Lean Manufacturing in practice

Programme and exercises

1. Introduction to Lean Manufacturing methodology:

• Lean history.
• 5 basic principles of Lean Manufacturing.
• Lean manufacturing versus Six Sigma.
• Lean implementation.
• Kaizen and Kaikaku.
• Objectives for implementing Lean Manufacturing in the company.

2. Lean in production process management:

• Types of waste.
• VSM value stream mapping.
• TPM and its tools (OEE, SMED, etc.).
• JiT.
• Kanban SIMULATION of a continuous flow.

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  3. Organization of the workplace:

• 5S.
• Elements of the process standard.
• Standard work content.
• Cycle time – Process cycle time.
• Takt time.
• Balancing the production line.
• Visual Management.
• Tools used in LM – The 5 “Why” method – 5 x why? Ishikawa diagram, Brainstorming.

Exercises

Discussion, examples, individual and group exercises:

• Muda analysis using film as an example.
• Drawing the value stream map step by step.
• OEE calculation SMED film analysis (4 steps).
• Kanban simulation game.
• 5S game.
• Analysis of line/manufacturing cell operation.