Lean Manufacturing for Job Shops
Lean
Manufacturing has proven to be the most powerful system yet developed for
improving a companies performance. Developed primarily in the automotive
industry, Lean has been mandated in most automotive plants and Tier 1 suppliers.
While spectacular results have been seen in stable, repetitive plants, little
attention has been focused on applying these same techniques to smaller sites
and Job Shops.
Most small plants and Job Shops attempting to go Lean do so using information
and techniques
created by and for large, repetitive factories. It is little surprise that most
of these companies are unable to duplicate the successes they read about. Refinements
in Lean Theory and 16 years of Lean experience have enabled Sterling to
successfully apply Lean techniques in non-repetitive manufacturing
environments.
THE WORKSHOP
This one-day workshop will provide
an in-depth view of Lean Manufacturing and the specific techniques required to
implement it in a Job Shop or Make-To-Order environment. This is a hands-on
workshop, not a seminar on theory.
We will engage in practical
exercises and simulations to demonstrate the use of many of the different Lean tools.
Attendees are encouraged, though not required, to bring a minimal amount of
their own production information to aid in understanding the application of
these techniques in their own plants. A copy of
the Lean software tools used during the workshop will be provided to each
attendee.
We will look in depth at each Lean tool and it's
application in a non-repetitive plant. We will focus on why Job Shops must use
the Lean tools differently. Specifically, we will look at the three areas of
a company that small shops MUST focus on to succeed with Lean.
Attendees will be requested to review some course materials
prior to the workshop. Details will be included in the registration confirmation package.
LEARNING OBJECTIVES
 |
Lean Manufacturing Overview - What
is Lean and what can it mean for your company. |
|
Managing A Lean Project
|
Picking a team |
|
Setting a vision and communicating
it to all your employees |
|
Assessing your pre-implementation
needs |
|
Picking your first battle |
|
Training your employees |
|
Implementation |
|
Ongoing assessment and adjustment |
|
|
Goals and Measures - Where are you
going and how do you know if you are moving in the right direction? Perhaps
the most powerful employee motivator, visual depiction of goals and clearly
understood measures are essential to Lean success. |
|
Performance Evaluation |
|
Value Stream Mapping - Learn to
use this most important Lean tool to identify the areas of waste in your
company. Focus your improvement efforts where they will make the greatest
impact. |
|
Just-in-Time Techniques in Job
Shops and Small Plants
|
Takt Time - Learn how to
establish a drumbeat in your plant that will control material flow.
Eliminate excess inventory and reduce wasted machine time, produce more
shipments with less production time. |
|
One Piece Flow - Increase
flexibility in your operations. Produce only what your customers want, when
they want it. JIT can work in Job Shops, it just needs a bit of adjustment. |
|
Pull Systems - Learn how to use a
pull system to control material flow on the plant floor. Use pull system
monitoring to indicate problems in production. Learn how pull systems can be
used in non-production areas as well. |
|
SMED - Possibly the greatest
impact of Lean is in the area of machine setups. You CANNOT become Lean
unless you can rapidly changeover your equipment. Learn the fundamentals and
use the software tools provided to begin cutting wasted setup time. |
|
Cells - Learn how to calculate
the advantages of cells in your plant. Learn how to create Virtual Cells in
departments that need to share resources. |
|
Kaizen Events - Where and how can they be used
in Job Shops? |
|
|
Quality Systems in Lean - Once you
have discovered areas of waste in your plant, learn how to use a structured
quality system to eliminate them.
|
ISO9000/QS9000 |
|
Six Sigma |
|
|
Lean Vendor Relations - For most
Job Shops, material procurement represents a substantial portion of delivery
leadtime. Learn to extend your material pulls systems to key suppliers and
even some customers. |
|
Continuous Improvement Culture |
