Lean Manufacturing Workshops 

LM1 - Shop Floor Value Stream Mapping Workshop (1 day)

Outline:

Identifying the value stream of a product line exposes waste by revealing steps that add no value, such as inspection, storage and rework. Traditional methods to reduce cost are organized by departments, not value streams, and therefore hide, rather than eliminate, waste. Conventional schemes to reduce cost do not address the key principles of lean thinking: Value Stream, Flow, Pull Systems and Quest for Perfection. This one day Workshop is ½ classroom and ½ shop floor, should have 8-12 shop floor personnel, including machine operators, material handlers and Production Managers. During the workshop we shall:

1. Teach Value Stream Mapping.
2. Map the current state of your process.
3. Develop a Future State Map.
4. Create an action item list, highlighting Kaizen Events needed to achieve the Future State.

(Return To Top)

LM2 -Leadership's Role in the Quest for Lean Workshop (2 hours)

Outline:

This 2-hour presentation explores the crucial role of Top Management in the successful launch and implementation of Lean Manufacturing within an Organization. This Presentation by Frank Nagy has given this overview to many Toyota suppliers embarking on Lean Manufacturing under auspices of the Toyota Supplier Support Center.

Kaizen (Continuous Improvement) Events are based on the Future State Value Stream. These Workshops are usually 2 or 3 days, and are one-third classroom and two-thirds shop floor or office. Kaizen Workshops should deal with a discrete, defined manufacturing or administrative operation, usually with 10-12 participants. 

(Return To Top)

LM3 - Lean Simulation Workshop (4 hours)

Outline:

This workshop lets participants discover the impact of Lean Thinking. The hands-on exercise teaches fundamental precepts of Lean Manufacturing. Participants will learn and practice Takt time, one-piece flow, JIT production, visual workplace, pull systems, work balance and continuous improvement. The 4-hour Workshop is done in a classroom with no more than 21 participants. It is suitable for assembly operators and office personnel. Two workshops can be done per day. 

(Return To Top)

LM4 - 5S Visual Workplace Workshop (1 day)

Outline:

This Event teaches a process and method for creating and maintaining an organized, clean, high-performance workplace where abnormalities are visible and obvious. The 5S workshop is designed to identify and eliminate waste in the work place, and will be the basis for continuing discipline and process improvement. The objective is to train people in your organization to do your own 5S Workshops, with limited guidance from us, as needed. The 5S Workshop is 1/3 classroom and 2/3 shop floor.

(Return To Top)

LM5 - Productivity Workshop (1 day)

Outline:

The Productivity Workshop, based on, and derived from concepts learned in Lean Simulation, Value Stream Mapping and 5S workshops, is rigorous and quantitative. The Productivity Event applies fundamentals learned in previous workshops to the shop floor. Participants measure assembly cycle times, and learn how these intervals relate to Takt time. By the end of the Productivity Workshop participants will know how to:

1. Set-up standardized work
2. Visually display operator cycle times
3. Balance operator cycle times to meet Takt time
4. Do standardized work combination tables
5. Plan a layout based on that standard work

(Return To Top)

LM6 - Built-in-Quality (Error Proofing) Workshop (1 day)

Outline:

This Workshop teaches how to select and use error-proofing (Poka-Yoke) tools to ensure built-in-quality. Once root cause is determined for a particular quality defect, the team will error-proof the process to prevent recurrence. Participants will learn how to:

1. Calculate and understand First Time Quality (FTQ)
2. Implement inexpensive, simple error-proofing devices
3. Use Standardized Work to support the operator without increasing work burden 
4. Avoid complex, expensive Quality Control Methods
5. Build JIDOKA (quality in station)
6. Develop quality problem solving circles

(Return To Top)

LM7 - Pull Systems Workshop (1 day)

Outline:

The Pull System Workshop teaches and demonstrates how product is pulled through the plant in response to customer demand. We shall use load-leveling tools (Heijunka Box) to smooth flow through the process to pace production to meet Takt time.During this workshop we shall:

1. Identify sites for kanban
2. Set-up Supermarkets and FIFO Lanes
3. Using the Value Stream Map, decide what types of kanban are needed, and plan how each will circulate
4. Design kanban cards
5. Determine the number of parts for each kanban
6. Calculate how many kanbans are needed
7. Decide quantity and location of buffers and safety stocks
8. Write kanban procedures and train users
9. Test the new pull system by monitoring flow and checking for lost, delayed and mishandled cards
   

(Return To Top)

LM8 - Manufacturing Problem Solving Workshop (1 day)

Outline:

This Event introduces concepts and methods to solve on-going manufacturing and/or assembly problems. The Workshop shows how pathways, drawing on reason, logic, common sense and imagination are used to systematically solve specific problems in the manufacturing or processes. Participants will be taught that problems are solved by a synergistic result of a diverse team using a structured approach to describe and define problems, hypothesize and test possible root causes, put solutions to work, and document corrective actions.  Participants will learn:

1. How to methodically approach different types of problems
2. Problem-solving traps
3. A step-by-step approach to find and analyze root cause(s) and discover solutions 
4. How to complete the PCDA (plan, do, check, act) cycle using tools such as Pareto charts, 5-why's analysis, cause and effect (Ishikawa) diagrams, problem analysis flow charts and Hoshin benchmarking methods

(Return To Top)

LM9 - Total Productive Maintenance Workshop (1 day)

Outline:

The goal of Total Productive Maintenance (TPM) is to maximize the effectiveness of shop floor equipment. TPM addresses all aspects of machine operation, is based on the Owner-operator approach and fits with other quality initiatives. During the Workshop participants will learn:

1. The objectives of TPM
2. The Six Big Losses that impair equipment effectiveness and decrease run time
3. How to calculate and understand Overall Equipment Effectiveness (OEE) 
4. How the Owner-operator improves OEE and increases run time

(Return To Top)

LM10 - Quick Changeover Workshop (1 day)

Outline:

The current state machine set-up, or changeover, is videotaped. The tape is analyzed by the team, and used to design a future state with reduced changeover and increased machine up time. Participants will:

1. Learn why adjustments are waste
2. Preset tooling and gauging before setup
3. Transfer internal to external steps 
4. Write standardized work
5. Develop procedures to examine, repair and store tools and gages
6. Use lifting devices, rollers and other mechanical devices to speed setup
7. Use positive stop devices to reduce adjustments
8. Locate prints, specs, and work instruction
9. Make standardized changeover instruction packets and learn how to schedule changeovers to minimize internal steps 
10. Simplify record keeping for training and tracking

(Return To Top)

LM11 - Manufacturing Systems Workshop (1 day)

Outline:

The Workshop takes a Lean approach to a new product line or manufacturing processes, and combines components of the Productivity, TPM and Built-in Quality Workshops done on existing products. We scrutinize customer demand, machine layout and capacity and work balance. We work with employees involved in planning and launching the new product or equipment to find the most efficient and least expensive process. During this Workshop we shall:

1. Document present state by calculating lead time, link machine capacity and operator balance to Takt time 
2. Design new equipment layout, calculate standard work in process, put tools and material at point of use, write standardized work for new jobs and define TPM and Built-in-Quality goals and methods.

(Return To Top)

Outline:

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

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

1. Review for test
2. MODAPTS Practitioner Certification test.

• MODAPTS Manual © 2004
• 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.

(Return To Top)

Constraints Management Training Overview:
A workshop focused on how to improve the performance of manufacturing systems (e.g. safely produce quality parts to schedule at minimum cost and with out added investment)

Target Audience:
Those responsible for manufacturing system design, improvement, and day-to-day operation.

Description:

This workshop provides insight and tools to effectively manage and optimize the performance of manufacturing systems through the application of Constraints Management principles as a key element of a Production System. Participants learn the concepts through the use of video segments followed by extensive group discussions. Topics include the importance of clear goals, impact of the measurements, local versus systems optimization, key definitions, and the 5-Step throughput improvement process. Various improvement strategies, including focused uptime improvement, elimination of constraint blockage and starvation, and improved operational/teamwork processes are also reviewed. At the close of the workshop, participants are engaged in a discussion regarding how to apply Constraints Management principles to their own work situations, and specific improvement ideas to optimize capacity, process, & policy constraints are identified and discussed.
Given limited resources in every organization and the tendency of the well-intentioned employees to try to work on "everything-everywhere", this workshop will help them better prioritize and focus scarce resources on those things that contribute the most to the goal of any business---making money.

Class Size: Typically ranges from 6 to 30 participants 

Duration: 2 to 4 hours.

Cost*: $150 (2 hr) or $300 (4 hr) per person 

(Return To Top)

Outline:
The goal of the this workshop is to define and apply the 8D Method for problem solving in manufacturing.  The basics of 8D Method has been used by Toyota, Ford, US Air Force and General Electric.  8D Method brings a disciplined approach to problem solving that involves cross-functional teams.  During the Workshop participants will learn:

1. The objectives of 8D Method
2. 8D Methodology steps in detail
3. Interactive problem solving using the 8D Method
4. Case studies using a simulated environment
5. How to apply 8D Method at your manufacturing facility

Dates: By arrangement
 
Location: On-site or PMC Offices, Dearborn, Michigan
 
Cost*: $1000/person or $6,000/workshop 

(Return To Top)

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