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Lean Manufacturing

When a cultural change initiative, such as the implementation of Lean techniques, is undertaken, a cultural analysis should be done. Issues that need to be addressed should be undertaken immediately but usually can be done concurrently with the implementation of the Lean Initiative. We can do the cultural analysis and help you monitor the changes needed. In addition we can do the initial training and teach you how to very quickly become self-sufficient in this area. Our uniqueness comes in the ability to quickly change your processes and show you how to make your processes Lean. We like to say that once we are on board, you need to come with your coveralls, because that’s when the work starts. Get ready to change and improve your processes.

The approach taken when implementing a Lean Initiative will vary but there are some common topics usually addressed early on in the effort and usually two levels of training are initiated; one at the management level, another at the worker level. Unlike most initiatives, there is no effort made to train all personnel before actions to improve your operation are undertaken. Quite to the contrary, implementation of some Lean Techniques will be ongoing with the first of the Management trainings. This will not only show the workforce that the Company is serious; but learning-through-doing is the most effective technique of all teaching methods. Not only that, but financial benefits begin to accrue almost immediately.


Training will give the following background information:

  1. Lean basics

    1. Problem  solving to reach the ideal state

    2. Thorough elimination of waste

    3. Using a fully engaged workforce

  2. Lean Manufacturing

    1. What it is

    2. It's origin

    3. Strengths and weaknesses

    4. Foundational issues to make it work -- This is an absolutely critical area which must be addressed

    5. The 7 Wastes

  3. The five leading indicators  of cultural change

    1. Leadership

    2. Motivation

    3. Problem solving

    4. Employee  Engagement

    5. Teaching/learning/experimenting

  4. The Effect of Variation on Manufacturing

    1. How variation effects output

    2. How variation effects economics

    3. How variation affects planning

    4. The concepts of dependent events and manufacturing

  5. The Theory of Constraints

    1. The three types of money in TOC

    2. Basic economic measures

    3. Bottleneck theory

    4. The Five Steps of Focusing

    5. How TOC attacks the 7 wastes

    6. Strengths and weaknesses of TOC

    7. Applicability of TOC

  6. The Metrics of Lean Manufacturing

  7. Toyota Production System as developed by T. Ohno

    1. JIT

    2. Autonomation

  8. Cellular Manufacturing as a Lean Concept

    1. Advantages and Disadvantages

    2. Dependency and variation effects

  9. Understanding the Value Stream

    1. Value stream mapping principles

    2. Mapping a real value stream

    3. Making Continuous Flow

  10. A Critical and Comparative Analysis of Various Philosophies including;

    1. Lean

    2. TOC

    3. Deming’s Management Obligations

    4. TQM

    5. Crosby’s Approach

    6. Six Sigma

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