Full course description
Lean Overview and Workplace Organization
This course covers lean manufacturing, the Toyota Production System (TPS), workplace organization, and the 5S Program. Learners will study in-depth topics like similarities and differences of traditional and lean manufacturing methods, visual management tools used in the workplace, and the 5S Program (sort, straighten, shine, standardize, and sustain).
Total Productive Maintenance
Lean Manufacturing teaches learners ways to identify and eliminate waste in order to improve quality, reduce production time, and decrease cost: distilling down manufacturing processes to what is value added. Total Productive Maintenance takes learners through key topics and skills including the importance of total productive maintenance and describing three principles of preventative maintenance, overall equipment effectiveness, implementing the elements of an autonomous maintenance program, and maintaining equipment including cleaning the equipment, eliminating sources of contamination, training, visual control methods, equipment inspection, and developing and testing standards.
Lean Process Flow
Lean Manufacturing teaches learners ways to identify and eliminate waste in order to improve quality, reduce production time, and decrease cost: distilling down manufacturing processes to what is value added. Lean Process Flow covers key concepts including elements of lean production, comparing push-and-pull production systems, the Kanban System and its benefits, the Replenishment Interval and its importance, production scheduling, production balancing, and flow production and its benefits.
Visual Workplace
Lean Manufacturing teaches learners ways to identify and eliminate waste in order to improve quality, reduce production time, and decrease cost: distilling down manufacturing processes to what is value added. Visual Workplace takes learners through key topics and skills including visual communication, elements of a visual factory, four types of visual devices, guidelines for a visual facility, selecting workplace borders, assigning location addresses and workplace territory, elements of the visual workplace, visual documentation, visual production control system, visual schedule display, visual quality system, visual production indicators, and creating and sustaining the visual workplace.
Introduction to Lean
Introduction to lean introduces the concepts, terms, and application of lean manufacturing principles and practices in the manufacturing process. Provides an overview of the history and evolution of lean, the benefits of lean process, and the role of management in the lean process.
Set-Up Reduction
Lean Manufacturing teaches learners ways to identify and eliminate waste in order to improve quality, reduce production time, and decrease cost: distilling down manufacturing processes to what is value added. Set-up Reduction includes concepts for learners such as setup and SMED overview including large-lot production; preparing for SMED including the four phases of traditional setup and transitioning from traditional to SMED; separating external setup and internal setup tasks; converting internal setup tasks to external setup tasks; and streamlining all setup tasks including stages 1-3 of SMED (implementation, tracking, and creating an action plan for open issues at the end).
5S
5S is the lean manufacturing technique that introduces principles and methods of workplace organization. Reviews the 5S tool for organizing and maintaining the workplace: Sort, Straighten, Shine, Standardize, and Sustain.
Poka-Yoke
Lean Manufacturing teaches learners ways to identify and eliminate waste in order to improve quality, reduce production time, and decrease cost: distilling down manufacturing processes to what is value added. Poka-Yoke covers key concepts such as zero quality control, terms defect and error, defect levels of a plant, types of inspection, poka-yoke systems, poka-yoke methods, poka-yoke devices, red flag conditions, contact method devices, fixed-value method devices, and motion-step method devices.
Lean Theory
Lean theory explores the concept underlying lean manufacturing theory: identifying and eliminating waste. Studies the elements, rules, and tools of lean theory and how to employ them to eliminate waste.
Kaizen
Lean Manufacturing teaches learners ways to identify and eliminate waste in order to improve quality, reduce production time, and decrease cost: distilling down manufacturing processes to what is value added. Kaizen teaches concepts to learners such as the term Kaizen and its role in manufacturing; Kaizen event planning including selection of a team, training, preparation, scheduling, and communication; Kaizen event implementation including rules, collection of data, performing a time and motion study, methods used for identifying and analyzing waste, types of reports and application; Kaizen event conclusion; and Kaizen event examples including how to perform a 5S Kaizen event, a Bottleneck Kaizen event, and a Lead Time Reduction Kaizen event.
Value Stream Mapping
Lean Manufacturing teaches learners ways to identify and eliminate waste in order to improve quality, reduce production time, and decrease cost: distilling down manufacturing processes to what is value added. Value Stream Mapping teaches key learning concepts to learners including value and value-added processes, value stream and the value stream map, preparation for value stream mapping, current state value stream mapping, process analysis using a value stream map, and future state value stream map and implementation.
Standardized Work
Lean Manufacturing teaches learners ways to identify and eliminate waste in order to improve quality, reduce production time, and decrease cost: distilling down manufacturing processes to what is value added. Standardized Work teaches the fundamentals of standards and standardization including different types and levels and their role in lean manufacturing, interpreting standardized work documents, how standards are created and communicated, and improving standards through systems such as Genba Kanri.
Six Sigma
This course covers Lean Six Sigma principles, project management, customer determination, team development and management, measurement, analysis, and improvement and control. Learners will study topics like customer value and expectations, team dynamics, data collection, normal distribution and probability, process capability, hypothesis testing, non-parametric analysis, design of experiments, and more!