Hands-On Introduction to Lean Principles - 101

Description:
For those seeking a clear foundation understanding of Lean principles, and/or those in a largely repetitive manufacturing environments, this one-day, interactive, hands-on, simplicity-driven workshop makes Lean Thinking and Lean Manufacturing principles easy to understand through the use a daylong learn-by-doing simulation. Participants become team members in the Sky-View Aircraft Company, a manufacturing operation that has to adopt Lean/World Class thinking to increase productivity to improve its competitive position to secure a large contract. The process is based on the understanding that it is people who make processes – and plants – successful and they do it by threading lean thinking, common sense, Value Stream Mapping, operations layout, quick setup, visual approaches, and more throughout a very busy one-day experience. This one-day program provides the 20% of the broad training that provides 80% of the value.

Using interlocking blocks (Lego) in the four-phase assembly process, team members work and learn together. They gather the data they need to understand the concepts as they assist their team in making the company successful. As they proceed, their results are captured visually. The participants become directly involved as they use the data they generate - not data given to them from a textbook.

Prerequisites:
None. However, to get maximum value, participants should be employed in a manufacturing/customer/ supplier infrastructure and have an appreciation of manufacturing operations. An awareness of the concepts covered in Lean Thinking by James P. Womack, or the Learning To See workbook will be beneficial. Bringing a copy of Learning to See to the workshop will be a benefit but is not required.

Specific Objectives:
Upon completion of this interactive simulation, participants will be able to:

List and explain each of the 5 steps to “Lean Thinking”
Describe what is communicated in a Value Stream Map and how the map is derived
Use simple Value Stream Mapping to clarify a present operation (Present State Map)
Describe the impact that plant layout and set-up time have on production
Describe a “Pull System,” its typical characteristics, and its typical effect on customers and quality
Define “Takt Time” and know how to calculate it
Explain how Takt Time can aid in the decision making process of deciding best choices
List the 7 forms of “Waste” and briefly describe each as it relates to his or her facility or environment
Brainstorm opportunities for improvement
Generate a “Future State Map” for a given product or process
Describe why a visual factory is desirable and the benefits derived from achieving one
Know how to create a visual factory using charts and visual indicators that show and monitor the status of key indicators/measures quickly, simply and effectively
Determine what is “Value Added” and “Non-Value Added” in a typical manufacturing environment

For further information contact us at info@hpsinc.ca

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