Expand All | Collapse All

 

Productivity Improvement in Operations

Productivity Improvement in Operations Workshops

PI1 Value Stream Mapping for Lean Manufacturing (1/2-day)
PI2 The Science of Lean Systems (1-day)
PI3 Overview of Supply Chain Optimization (1/2-day)
PI4 Principles of Lean Manufacturing (1/2-day)
PI5 Production Management  
PI5-1 Module 1: Forecasting (1/2-day)
PI5-2 Module 2: MRP I, MRP II, and ERP (1/2-day)
PI6 Finite Capacity Scheduling Techniques for Effective Shop Floor Control (1/2-day)
PI7 Factory Layout and Material Flow  
PI7-1 Module 1: Fundamental Concepts in Facility Layout (1-day)
PI7-2 Module 2: Material Flow Simplification in Job Shop Type Manufacturing Facilities (3-days)
PI8 Theory of Constraints* (2-days)
PI9 Scheduling Using Asprova Finite Capacity Scheduling Software (3-days)
PI10 Business Process Modeling Using ARIS (1/2-day)
PI11 MODAPTS Practitioner Certification (2 1/2-day)

PI1- Value Stream Mapping for Lean Manufacturing (1/2-day)

Course Outline:
  1. Lean Manufacturing, JIT, and Value Stream Mapping (VSM)
  2. VSM Process
    • Guidelines for VSM
    • VSM Icons
  3. Steps of Mapping the Current State
  4. Designing the Future State Map
    • Takt Time
    • Continuous Flow
    • Kaizen
    • Pacemaker Process
    • Leveling the Production Mix
    • EPEt
  5. Outlining a Work Plan for Action

Course Material:

  1. Mike Rother and John Shook, Learning To See: Value Stream Mapping and Create Value and Eliminate Muda, 1998. (Add $50 for course book)
  2. Course Manual

Dates:   By arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $300/$350 per person


Return To Top (Return To Top)
PI2 - The Science of Lean Systems (1-Day)

Course Outline:
  1. Defining a Manufacturing System
    • Prescriptive and Descriptive Models
    • The Systems Approach
    • Models and Performance Measures
  2. Basic Factory Dynamics
    • Definitions
    • Internal Bencmarking
    • Best Case, Worst Case, and Practical Worst Case Performance
    • Labor Constrained Systems
    • Case Study
  3. Variability Basics
    • Process Time Variability
    • Causes of Variability
    • Flow Variability
    • Variability Interactions-Queueing
    • Effects of Blocking
    • Variability Pooling
    • Case Study
  4. The Corrupting Influence of Variability
    • Variability Laws
    • Flow Laws
    • Batching Laws
    • Cycle Time
    • Diagnostics and Improvement
    • Case Study
  5. Push (MRP), and Pull (Kanban, CONWIP) Systems
  6. The Human Element in Operations Management

Course Material:

  1. Hopp and Spearman, Factory Physics, McGraw-Hill, 2000. (Add $100 for course book)
  2. Course Manual

Dates:   By arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $550/$650 per person


Return To Top (Return To Top)

PI3 - Overview of Supply Chain Optimization (1/2-Day)

Course Outline:

  1. Definitions and basic concepts.
  2. Descriptive models related to supply chains.
    • Forecasting models
    • Cost models
    • Resource usage models
    • Simulation models
  3. Business motivations.
  4. Basic decisions and value-enhancement opportunities.
  5. Modeling, solution, and optimization methods.
  6. Application categories.
    • Strategic applications
    • Tactical applications
  7. Demonstration of supply-chain-modeling software.
  8. Multiechelon supply chains.
    • Inbound supply chains
    • Outbound supply chains
  9. Performance measures
    • Financial metrics
    • Channel alignment
    • The bullwhip effect and its amelioration
  10. Predictions and summary. 

Course Material:

  1. Course handouts provided to attendees
  2. Modeling the Supply Chain, by Jeremy F. Shapiro, (c) 2001 by Thomson Learning Incorporated, Pacific Grove, California.

Dates:   By arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $300 per person


Return To Top (Return To Top)

PI4 - Principles of Lean Manufacturing (1/2-Day)

Course Outline:

Learn basic principles of Lean Manufacturing:
  1. Workshop Safety, Order, Cleanliness
  2. JIT Production
  3. Empowered Teams
  4. Visual Management
  5. Kanban/Pull Systems
  6. Continuous Flow Processing
  7. Work Balance Charts
  8. Leveling

Course Description:

This workshop teaches fundamental precepts of the Toyota Production System to office and shop floor personnel. The simulation exercises allow participants to "discover by doing" the impact of Lean Thinking.

Course Material:
  1. Course material provided to attendees

Dates:   By arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $300 per person


Return To Top (Return To Top)

PI5 - Production Management

  PI5-1 - Production Management: Forecasting (1/2-day)

Course Outline:
  1. Introduction to Forecasting
    • Criteria for Forecasting
    • Forecasting Horizons
    • Role of Forecasting
  2. Forecasting Methods
    • Qualitative Techniques
    • Quantitative Techniques
  3. Time-Series Forecasting
    • Moving Averages
    • Exponential Smoothing Techniques
    • Regression Analysis
    • Seasonal Smoothing Techniques
    • Error Analysis
    • Other Techniques
  4. Group Forecasting
  5. Linking Forecasting and Inventory Management
  6. Forecasting Software
Course Material:
  1. Forecasting Book. (Add $75 for course book)
  2. Course Handout
Dates:   By arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $300/$375 per person

Return To Top (Return To Top)
  PI5-2 - Production Management: MRP I, MRP II, and ERP (1/2-day)

Course Outline:
  1. MRP I: Material Requirements Planning Basics
    • Overview of MRP
    • The MRP Procedure
    • Bill of Material (BOM)
    • MRP Inputs and Outputs
  2. Lot Sizing in MRP
    • Lot-for-Lot
    • Fixed Lot Size and EOQ
    • Fixed Order Period
    • Part-Period Balancing
    • Wagner-Whitin Method
  3. Safety Stock and Safety Lead Times
  4. Problems in MRP
  5. MRP II: Manufacturing Resource Planning
    • Long-Range Planning
    • Intermediate Planning
    • Capacity Planning
    • Short-Term Control
  6. ERP: Enterprise Resource Planning
  7. Manufacturing Execution Systems
  8. Finite Capacity Scheduling
Course Material:
  1. Course Manual
  2. Course Book (Add $75 for course book)
Dates:   By arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $300/$375 per person

Return To Top (Return To Top)
PI6 - Finite Capacity Scheduling Techniques for Effective Shop Floor Control (1/2-day)

Course Outline:
  1. Shop Floor Control (SFC)
    • Gross Capacity Control
    • Bottleneck Planning
    • CONWIP Configurations
    • TOC Technique
    • Kanban
  2. Production Tracking
  3. Production Scheduling
    • Simulation-Based Scheduling
    • Optimization-Based Scheduling
    • Disbatching Rules
    • Optimal Batching
    • Forward, Backward and Mix Scheduling
  4. Due Date Quoting
  5. Bottleneck Scheduling
  6. Implementing a Scheduling System
  7. Finite-Capacity Scheduling Software
Course Material:
  1. Course Manual
Dates:   By arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $300 per person


Return To Top (Return To Top)
PI7 - Factory Layout and Material Flow

  PI7-1 - Fundamental Concepts in Facility Layout (1-day)

Course Outline:
  1. Introduction to Facility Layout
    • Symptoms of Poor Material Flows in a Facility
    • Checklist for Assessment of a Facility Layout
    • Traditional Layouts for Component-manufacturing Facilities
    • Traditional Layouts for Assembly Facilities
  2. Design for Flow (DFF): Scientific Principles for Design of Facility Layouts
  3. Data Requirements and Charting Techniques
  4. Role of Process Analysis and Improvement in Design of a Facility Layout
  5. Overview: How to Design a Facility Layout
  6. Classical Methods for Design of a Facility Layout: Systematic Layout Planning
  7. Classical Methods for Design of a Facility Layout: Production Flow Analysis
  8. PFAST: A Computer Package for Production Flow Analysis
  9. Video Screening and Discussion: Facility Layout for JIT Manufacturing
  10. Case Study: Layout Design for a Make-To-Order Assembly Facility
  11. Case Study: Design of a Flexible Shopfloor Layout for a Fabrication Jobshop
Course Material:
  1. Course Manual
Dates:   By arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $500 per person


Return To Top (Return To Top)
  PI7-2 - Material Flow Simplification in Job Shop Type Manufacturing Facilities (3-days)

Course Outline:

Day 1
  1. Introduction to Facility Layout
    • Exercise: Process Layout Design for a Jobshop using Activity Relationship Charts
    • Exercise: Process Layout Design for a Jobshop using From-To Charts
  2. Checklist for Assessment of a Facility Layout
  3. Traditional Layouts for Facilities
  4. Data Requirements and Charting Techniques
  5. Process Analysis and Improvement
    • Exercise: Process Analysis and Improvement in a Food Processing Environment
  6. Design For Flow (DFF): Scientific Principles for Design of Facility Layouts
  7. Production Flow Analysis (PFA) for Facility Layout
  8. PFAST: A Computer Package for Production Flow Analysis
    Exercises on the Industrial Application and Integrated Use of PFAST Analyses
    • Factory Flow Analysis for Design of Focused Factories
    • Design of a Facility Layout for Multiple Part Families with Overlapping Machine Requirements <
    • Flow Analysis and Layout Design for a Multi-Part Machining Cell
    • Introduction to Group Technology
    • Minimization of Setup Changeovers on Manufacturing Equipment
Day 2
  1. Cell Formation using Machine-Part Matrix Clustering
  2. Cell Formation using Operation Sequence Clustering
  3. Cell Formation using Group Technology
  4. Design of Hybrid Cellular Layouts for Jobshops
  5. Design of Modular Layouts for Jobshops
  6. Facility Layout using Multiple Part Samples
  7. Multi-Period Stability of Cellular Layouts
  8. Layout Design for Assembly Facilities
  9. Case Study: Design of a Lean Flowline Layout for Low-Volume Machining of Crankshafts
  10. Case Study: Design of a Flexible Shopfloor Layout for a Fabrication Jobshop
  11. Case Study: Design of a Multi-Product Flowshop for Wired Equipment Assembly
  12. Performance Evaluation of Facility Layouts
  13. Computer-Aided (not Automated) Facility Layout
    • Software for Layout Design
    • Software for Layout Evaluation
  14. Design of Next Generation Factory Layouts (NGFL)
    • New Ideas and Methods for Facility Layout
    • Facility Layout: The Next Generation of Theory and Practice

Day 3

  1. Team Project Work
  2. Software Demos: Tools for Computer-assisted Facility Layout

Team Project Work: 

Each company team will receive the PFAST Analysis Report - this is a set of computer-generated outputs from PFAST using the sample of routings that they had sent prior to the workshop. They will have the opportunity to utilize those outputs as the basis for designing a new facility layout, a pilot manufacturing cell, etc. Throughout the day, the instructor will provide each team input and guidance on the use of the computer outputs to design their facilities.

Course Material:
  1. Course Manual
Dates:   By arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $1500 per person

Return To Top (Return To Top)
PI8 - Theory of Constraints (TOC)* (2-Day Workshop)
*Jointly with Goldratt Institute

Course Outline:
  1. Key Definitions: Throughput, Inventory, Operating Expense.
  2. Local versus Systems Optimization
  3. Impact of Measurement Systems
  4. Impact of Dependency and Variability
  5. Bottlenecks versus Constraints
  6. Impact of Blocking and Starvation
  7. Buffer Strategies
  8. Five-Step Process for Improvement
  9. Balanced versus Unbalanced Systems
  10. Constraints Management Fit with Lean Manufacturing

Course Description:

Workshop focuses on how to effectively manage and optimize the performance of manufacturing systems to improve output, shrink lead time, and control costs. Participants internalize concepts through the use of computer simulators, video segments, and extensive group discussions.

Who Should Attend:

Those responsible for manufacturing systems design, improvement, and day-to-day manufacturing management.

Course Material:

  1. Participant Workbook

Prerequisite:

If possible, the participants should read "The Goal" by Eli Goldratt in advance of the workshop.

Dates:   April 26-27, 2001 or by arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $995.00 per person


Return To Top (Return To Top)
PI9 - Scheduling Using Asprova Finite Capacity Scheduling Software (3-Days)

Course Outline:
  1. Asprova System Structure
    • Graphical User Interface (GUI)
    • Asprova Monitors
    • Automation Client ( Asprova Remote Access)
    • Internet Capability ( Asprova Talk Server)
    • Asprova-Visual Basic/Asprova-Visual C++ Integration
    • Asprova-ERP Integration
  2. Asprova Data Input
    • Asprova Table Structure
    • Project Settings
    • Data Sequencing
    • Case Study 1 - Asprova Table Creation
  3. Scheduling in Asprova
    • Scheduling Parameter Settings
      • Job Dispatching Rules/Settings
      • Schedule Optimization/ Weight Settings
    • Scheduling Settings
      • Forward/Backward/Mixed Scheduling
      • Order Targeting
    • Case Study 2 - Asprova Sample Creation
  4. Schedule Output Analysis
    • Asprova Graphs/Charts
      • Gantt Chart, Order Status, Resource Utilization, Inventory
      • Tardy Jobs, Order Lateness, Order Lead Time, Order Wait Time
      • Bill of Materials (BOM)
    • Asprova Reports
    • Asprova Re-Scheduling
      • Drag and Drop Functionality, Tardy Lot Identification
      • Lot Division, Job Resource/Time Fixing, Bottleneck Resource Identification
  5. Asprova COM Development
    • COM Development Overview
    • Asprova Plug-ins
    • Asprova Macro Creation
    • Case Study 3 - Sample Plug-in Creation Using Visual Basic
Course Material:
  1. Asprova Manual
  2. Introduction to Asprova Hand Out by PMC
  3. Asprova Introductory CD ROM
  4. Asprova Software Trial version
Dates:   See Asprova Seminar Dates or by arrangement

Location:   On-site or PMC Offices, Dearborn, Michigan

Cost*:   $1,500 per person


Return To Top (Return To Top)
PI10 - Business Process Modeling Using ARIS (1/2 day)

 

Outline:
  1. Why Business Process Modeling?
  2. The Concept of an EPC (Event-Driven Process Chain)
  3. The ARIS House (ARIS Structure)
  4. Modeling an EPC with Functions, Events, and Rules
  5. Documenting an EPC with Resources
  6. Summary and Conclusions
Course Material
  1. Business Process Modeling with ARIS (by Rob Davis)
  2. Course Manual
Dates: By arrangement 

Location: On-site or PMC Offices, Dearborn, Michigan 

Cost*: $200 per person


Return To Top (Return To Top)
PI11 - MODAPTS Practitioner Certification Workshop (2 1/2 day)

 

Outline:

Day 1
  1. Introduction to MODAPTS 
  2. Why use MODAPTS
  3. MODAPTS arm & trunk movements
  4. Movement exercises
  5. MODAPTS Terminal Activities
  6. Simultaneous motions
  7. Simultaneous exercises
  8. Terminal Activity exercises
Day 2
  1. Advanced Simultaneous exercise 
  2. Auxiliary MODAPTS Movements
  3. Auxiliary exercises
  4. Assembly observation & MODAPTS coding
  5. Assembly Operation exercises & MODAPTS coding
  6. Video MODAPTS study & rating exercise
  7. Case study exercise. Watch study vs. MODAPTS
Day 3 (1/2 day)
  1. Review for test
  2. MODAPTS Practitioner Certification test.
Course material provided to attendees:
  • Latest MODAPTS © Manual
  • MODAPTS Quick-Reference card
  • All required classroom materials
Upon successful passing of test, students are certified as a Practitioner of MODAPTS by the International MODAPTS Association.

 

Dates: June 9-11, July 14-16, Aug. 25-27, Sept. 22-24, Oct. 27-29, Nov. 22-24

Location: On-site or PMC Offices, Dearborn, Michigan

Cost*: $850 per person 

Return To Top (Return To Top)

*Workshop fees noted are subject to change based on class size, location, etc.