G3 Solutions, Inc.

COURSE: LEAN MANUFACTURING OVERVIEW
Companies responding to cost pressures must understand how lean principles and techniques can improve operations, reduce costs and increase profit margins. Lean Manufacturing can be an invaluable tool for keeping an organization running effectively while maintaining profitability.

In this workshop, each participant will understand the 7 forms of waste, non-value added activity, the steps associated with cellular manufacturing and the importance of 5S and value stream mapping.

Concepts Covered:

  • JIT Inventory Management
    • Pull vs. push systems
    • Traditional manufacturing promotes inventory stock piling
    • Lean manufacturing removes excess inventory
    • Quickly respond to customer demands
  • Value Stream Mapping
    • Identify value-added activities in the production stream
    • Determine:
      • What processes add value
      • What processes are essential
      • What processes do not add value and can be eliminated
  • Product Grouping and Cell Development
    • Single piece workflow manufacturing processes
    • Product grouping to minimize floor space
    • Flexible cells for variable production rates and inventory control
  • Identifying and Eliminating the 7 Areas of Waste
    • Rework or error correction, overproduction, excess inventory, extra processing, motion, wait time and transportation
  • Visual Workplace
    • Maximizing communication through visual imagery
  • 5S – Creating a Productive Workplace
    • Sorting, Simplifying, Systematic Cleaning, Standardizing, Sustaining
  • Standardization
    • Develop robust processes
    • Establish written and followed procedures
  • Self-Managed Work Teams
  • TPM – Total Predictive Maintenance
  • Poke-A-Yoke (Error/Mistake Proofing)