Lean Practitioners Certification for Manufacturing (5 Days) Program Participants: MODULE-6 (Standardization) This program is designed for the managers, engineers and • What is an standardized system professionals working in the manufacturing and transactional • Advantages of standardization environment, who want to equip themselves with the knowledge and • Degrees of standardization skills necessary to be effective change Agents and Lean Advocates • Development of Standard Operation Procedure and Practitioners in their organization. MODULE-7 Program Overview (Visual Management) • Why Visual Management Lean Program which is often known simply as "Lean", is a generic • Benefits of Visual Management process management philosophy derived mostly from the Toyota • Levels and steps of Visual Management Production System (TPS). It is a powerful method that allows Tools of Visual Display and Visual Control MODULE-8 organizations to improve the productivity, efficiency, and quality of MODULE-8 their products or services. Companies today, from a wide range of (Poka Yoke) industries, government agencies and other areas are finding ways to • Poka Yoke Philosophy apply the principles of lean as a means of producing goods and • Error & Defect delivering services that creates value for the customer with the • Poka Yoke Devices minimum amount of waste and the highest level of quality. Our • Poka Yoke System simulation-based, hands-on workshop will present you with essential MODULE-9 principles, tools and applications of Lean in any environment – (Flow and Work Cell Design) Manufacturing and Transactional. • What’s Flow? • Traditional layout & Lean layout Program Objective • What’s Workcell? Upon the completion of this program, the participants will be able • Prerequisite of Workcell to: • 9 steps for Workcell Design .Understand the Lean Principles and Tools MODULE-10 .Discuss the Lean Deployment Strategy and Framework (Standardized Work) .Conduct Value Stream Maps of the Current State and Develop a • What is Standardized Work Future State • Difference between Work Standard & Standardized Work .Identify Wastes and use critical Lean Tools to Eliminate Wastes • Steps of Standardized Work .Define the Improved Flow and Process in Simulated Manufacturing & MODULE-11 Transactional Environments. SMED (Quick Change Over) .Apply the Lean Principles and Tools at their Workplace and Lead • What is SMED Projects. • Waste during Change Over (C/O) or Setups .Improve the Overall Efficiency of the Factory Operations including • Benefits gained from reducing C/O times the Support Areas. • Procedures for observing & recording internal & external C/O activities Program Outline • Methods for reducing C/O times MODULE-1 MODULE-12 (Introduction to Lean) (Pull System Introduction) • Why “Lean” • What is “Pull” • History of lean5 principles of lean • Prerequisites of Pull System • Lean and Toyota Production System • Order Analysis • Lean and six sigma • How to choose different Pull systems MODULE-2 • Pull System Rules (Waste Identification) • Introduction of Supermarket Model • Define Customer Value-add and Business-Value add MODULE-13 • 7 wastes (Kanban) • Identify the causes of 7 wastes • What’s Kanban? • Muda, Mura & Muri • Kanban Functions MODULE-3 • Kanban Types and Application (Value Stream Mapping) • Kanban Calculation • What is value stream MODULE-14 • The purpose of a Value Stream Map (VSM) (Pacemaker & Heijunka Determine Pacemaker) • Develop a Current State Value Stream • Why Heijunka • Map of a process • Heijunka Elements &Sequence • Analyze a Current State Map for quick wins • Heijunka Box • Develop a Future State Map • Water Spider Route • How to implement VSM • Heijunka Application MODULE-4 MODULE-15 (5S-Workplace Organization) (Upstream Process Pull) • Why 5S • Manage upstream process from Pacemaker • What is 5S • Trigger Withdrawal Kanban • Step by step 5S Implementation • Control upstream batch process from Supermarket MODULE-5 MODULE-16 (Total Productive Maintenance) (Kaizen) • What is TPM & TPM Metrics • What is Kaizen • Six Losses of Equipment and OEE calculation • Kaizen Spirit • 4 phases of TPM • Main Kaizen Activity • 7 steps of TPM .