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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

Upcoming Dates

Not Scheduled

REGISTER HERE

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

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Lean Manufacturing Overview - What is Lean and what can it mean for your company.

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Managing A Lean Project
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Picking a team

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Setting a vision and communicating it to all your employees

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Assessing your pre-implementation needs

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Picking your first battle

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Training your employees

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Implementation

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Ongoing assessment and adjustment

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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.

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Performance Evaluation

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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.

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Just-in-Time Techniques in Job Shops and Small Plants
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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.

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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.

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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.

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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.

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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.

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Kaizen Events - Where and how can they be used in Job Shops?

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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.
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ISO9000/QS9000

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Six Sigma

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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.

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Continuous Improvement Culture

In each of these areas, we will focus on understanding the Lean Theory, and what modifications are required to apply it in a non-repetitive manufacturing plant.

Open Enrollment Workshop Fee - $250 per attendee

 

Fee includes Workshop, take-home materials and a CD-ROM with all software tools covered in the Workshop

Click here to check for workshop dates or register

"We have made great progress in just a couple of weeks with the knowledge we gained at your workshop. The software tools alone were worth the price of the workshop."  - Carl Ross, VP Manufacturing

"Using our own information in the exercises, we already have a To-Do list to begin working on when we get to the plant in the morning. It was an eye-opening day." - Paul Baker, Plant Manager

 

Copyright 2002 - The Sterling Management Group

P.O. Box  1578

Waitsfield, VT 05673

(802) 496-5900