Louisiana Tech University Lean Manufacturing Courses

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1 Lean Course Objectives: Your Employees will be able to: Louisiana Tech University Lean Manufacturing Courses Understand the tools, terms, terminology, and most importantly the benefits of Lean Manufacturing. Conduct Value Stream Mapping identifying current state of your operation identifies the potentials that will reduce waste and improve product flow, and develop a future mapping to reduce waste. Participate in the total development of your site specific lean implementation road map. They will also be able to avoid the common problems encountered during lean implementation. Lean Process Certification - Certificate #1: The Principles & Theory or Lean Lean Self-Assessment Lean Workplace Organization Lean Work Design Value Stream Analysis and Mapping Lean Setup Reduction Course 1 The Principles and Theory of Lean Module 1: Why Lean Manufacturing? The absolute needs to be customer focused, meet deadlines, and flexible and fast at all times. Make work flows standard and simple through consistent continuous flow, minimizing work in progress, and through use of visual measures. Manage capacity by increasing your up time, reducing your setup times, and finding lost capacity. Work to eliminate waste by identifying non-value added activities, modify, combine or eliminate tasks. Just in Time inventory management means not too early and never late; not just-in-case inventory but just-in time production and delivery; products will always be made right initially; equipment must always work. Module 2: Lean Terms and Terminology Lean Terms Lean Tools Lean Techniques Module 3: The Art of Waste Elimination through Lean Match lot sizes to customer demands through process controls and end work in process (WIP). In scheduling use pull instead of push scheduling. Schedule to the rate-determining step (the bottleneck), then debottleneck process lines. Facilitate to ensure fast feedback by arranging sequential operations next to each other which ensures fast feedback from internal customer operation to internal supper operation if something in-process is not right.

2 Module 4: Lean Thinking and the Thought Processes Eliminating waste is not just a concept for manufacturing. The techniques can be utilized in all production situations like office, sales, finance, maintenance, healthcare, and even R&D processes and procedures. Lean along with Six Sigma complement each other. Successful implementing of lean concepts to eliminate production and inventory wastes will be demonstrated. Course 2: Lean Self-Assessment Module 1: Continuous Improvement Learn how to fight the not created or invented here attitudes and will learn how to leverage successes. Learn to use Kaizen events targeting processes for rapid improvement in order to achieve the future state of the Company. (Kaizen events are an extremely efficient way to quickly improve a process) Use a standardized Problem-Solving model Define, Measure, Analyze, Improve, and Control (DMAIC). Module 2: Support Processes See that Lean Techniques will require changes in Purchasing, Scheduling, Warehousing, Shipping, and Accounting practices. You will be given case studies that demonstrate the success of lean concepts in various sectors. Course 3: Lean Workplace Organization Module 1: The Roadmap for Lean We will start this module identifying the people issues. Employees focus is on workplace organization (the 5S s); we use the value stream and process workflow analysis to establish effective workplace layouts. Where we focus next depends on the companies specific needs. We will use targeted Kaizen events to speed up the changes. In this module we will also look at the need to modify support processes like scheduling and purchasing. Module 2: Workplace Organization accomplished through use of the 5S s System Employees learn and implement the 5s s System within their organization. The system consists of: Sort - the clearing of the work area Set in Order - designating locations Shine - the cleanliness of and appearance of the workplace Standardize - all employees doing things the same way Sustain This will ingrain the concept into the work culture. Forms and check lists needed for 5s implementation will be included in this module.

3 Course 4: Lean Work Design Training Duration: 1 day - 8 hours Cost per Person: $395 Module 1: Principles of Work Design Learn what work design is and what activities can be considered to be a part of the field. Learn how to re-design work stations to save motion wastes. Learn what causes Musculoskeletal Disorders (MSDs) in workplace and costs associated with MSDs. Module2: Risk Analysis Topics covered in this module include: Safety risk factors Job safety analysis tools: Rapid Upper Limb Assessment (RULA), Rapid Entire Body Assessment (REBA) National Institute for Occupational Safety and Health (NIOSH) lifting equation Sources of safety hazards: the work itself, manual lifting, back belts, workstation, work piece, work environment Module 3: Workstation and Tool Design Topics covered in this module include: Things to avoid in designing workstations Work height setting Chair design Workstation layout Job motion design Hand tool design Module 3: Work Design Practice Learn techniques to identify production waste due to improperly designed work methods and workstations. Learn the steps for developing an in-house work design program to achieve lean production. Examples of successful implementation of work design principles will be demonstrated. Course 5: Value Stream Analysis and Mapping Duration: 16 hours Cost per Person: $795 Module 1: Value Stream Analysis Learn to map your process from incoming order to outgoing product. To accomplish this we define process goals, create the current state map, and establish process metrics. Use the current state map to identify all potential improvements to the process. Module 2: Value Stream Mapping Learn to identify process goals. Collect and analyze process data from a simulated workplace or factory. Create a focused macro-facility work flow to determine how to minimize high volume travel distances. Conduct a micro-process workflow to apply cellular concepts, identify and remove bottlenecks, and move to pull processing or manufacturing.

4 Course 6: Lean Setup Reduction Module 1: The Eight Components of Lean Overview of eight components of Lean which are Value Stream Mapping, Workplace Organization, Predictability and Consistency, Set-up Reduction, TPM, Visual Factory, Support Processes, and Continuous Improvement. Module 2: Set-up Reduction Learn to apply Single Minute Exchange of Die (SMED) concepts, one of the many lean production methods for reducing waste in a process. Learn how to separate external tasks (which are external to the process) from internal tasks. Case studies showing successful implementation of SMED will be demonstrated. Lean Manufacturing Process Certification - Certificate #2: Lean Total Productive Maintenance Lean Layout and Flow Options for Manufacturing Predictability and Consistency Specialized Design Training for Lean Using Lean Baseline Tools Lean Process Training Course 7: Lean Total Productive Maintenance Module 1: Total Productive Maintenance (TPM) Why machines fail? How soon will a machine fail? How to estimate mean time to failure (MTTF) What is TPM? Why TPM? Module l develops operator involvement in equipment and helps them begin predictive maintenance practices. Module 2: Types of Maintenance Total Productive Maintenance (TPM) verses Preventative Maintenance (PM). Breakdown Maintenance Periodic Maintenance Predictive Maintenance Corrective Maintenance Maintenance History Module 3: TPM Targets Obtain overall equipment effectiveness (OEE) Operate in a manner so that there are no customer complaints Target to reduce manufacturing costs Achieve 100% success in delivery of goods to customer Maintain a safe and accident free environment Develop multi-skilled and flexible workers

5 Module 4: Three Stages in the Implementation of TPM Introduction Stage Announcement by management introducing TPM Initial education for TPM Setting up TPM and Department groups Implementation Stage Establish the TPM working system and target Institutionalizing Stage Develop a master plan for institutionalizing TPM Course 8: Lean Layout and Flow Options for Manufacturing Module 1: Lean Layout Options Learn about Lean layouts and the purpose for the layouts techniques and the topics covered include: Increasing moving cubic feet (not numbers of items) Eliminating crossover points Arranging the process to flow naturally Linking the processes to minimize time and distance Moving equipment together to simulate a continuous flow Putting internal customers and supplies next to each other. Exploring the various typical layout options. Modern software for plant layout applications. Course 9: Predictability and Consistency Specialized Design Training for Lean Duration: 16 hours Cost per Person: $795 Module 1: Predictability and Consistency Use Design for Manufacturability (DFM) and Design for Assembly (DFA) to design quality processes. Use of Gauge Repeatability and Reproducibility (GR&R) ensuring measurement systems are in place. Employ Statistical Process Control (SPC) to help ensure processes are both predictable and stable. Reduce variation and improve process capability through predict, prove, perform measures of Design of Experiments (DOE). Learn to eliminate the root cause of defects using problem-solving and mistake proofing techniques. Lastly learn to move to Six Sigma Quality. MiniTab software application examples will also be demonstrated in this class. Module 2: Continuous Improvement Learn how to fight the not created or invented here attitudes and will learn how to leverage successes. Learn to use Kaizen events targeting processes for rapid improvement in order to achieve the future state of the Company. (Kaizen events are an extremely efficient way to quickly improve a process) Use a standardized Problem-Solving model Define, Measure, Analyze, Improve, and Control (DMAIC).

6 Course 10: Using Lean Baseline Tools Module 1: Lean begins with Your Employees Communicate to your employees the why, what, how, and who of Lean. Education will be provided in all the concepts of Lean. Employees will be trained in the tools and techniques of Lean to achieve a flexible workforce. Module 2: Lean is driven by Data and Information All efforts will be focused on projects that lead to tangible savings. Here calculation techniques will be employed to generate data using time studies, equipment loading, rate (TAKT) time, staffing requirements, process yields, and cost of quality (COQ) results. Use of sample worksheets like Lean Project Summary, Cell Target Worksheet, Data Collection Form for Basic Equipment and Utility Parameters, Value-adding Analysis Worksheet, Process Change-over/Setup Worksheet, Set-up Reduction Worksheet, Cubic Feet Analysis Worksheet, and Lot Size Worksheet. Course 11: Lean Process Training Module 1: Training your employees the different steps in Process Training Learn use of a status display of performance for dashboard or balanced measures and Cost of Quality (COQ) results. Learn that visual controls such as sensory alerts will indicate if something is out of place. Learn that markings on the floor and different types of alarms will all help build a visual infrastructure. Module 2: Lean Inventory Practices Design the warehouse to work for them which will minimize trips to and from the warehouse. Use activity based costing (ABC) inventory categories prioritizing needs and storage locations. Module 3: Pitfalls that can be involved with Lean The lack of documenting the financial savings and the impact of that savings. The lack of commitment from the leadership to support and see the process through. Continuing to use traditional purchasing practices. Failing to change scheduling techniques. Not addressing the issues of the employees or the workforce in general. Never mistake-proofing or truly identifying the root cause. The misnomer that Lean is only for manufacturing. Not using the appropriate technology. Not truly leveraging the successes. Not knowing that you have gotten too Lean. Failing to continually analyze and unable to hold the gains.

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