Lean Manufacturing Practitioner Training

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1 Lean Manufacturing Practitioner Training Eliminate waste and maximize customer value kpmg.com/eastafrica/mc

2 Lean Manufacturing Practitioner Training Lean Manufacturing is a way to eliminate waste, reduce cycle time and improve efficiencies in a manufacturing environment. Lean focuses on flow, the value stream and eliminating muda, the Japanese word for waste. Lean manufacturing is the production of goods using less of everything compared to traditional mass production: less waste, human effort, manufacturing space, investment in tools, inventory, and engineering time to develop a new product Many manufacturing organizations waste 70%-90% of available resources through improper management of material, time, information, idle equipment, and inventory. Lean manufacturing offers tangible solutions in an effort to drastically cut this percentage of waste, improving quality, productivity and profitability in organizations. The fundamentals of lean manufacturing practitioner training embrace the identification and elimination of waste throughout the entire value chain, ultimately resulting in a more efficient manufacturing environment. KPMG s three day training course provides an in-depth coverage of Lean Manufacturing technologies and how each practice is linked together and applied to a corresponding business goal it contains numerous real-world examples based on production challenges in a variety of industries. The bottom line benefits to be addressed include lower production costs, higher profits, superior quality, and shorter order to deliver time, lower inventories, greater flexibility and improved response to changing customer demand. Guidelines for achieving these benefits are included. KPMG s Lean seminar explains why lean manufacturing works and clarifies the underlying philosophy by focusing on strategic outcomes rather than just tools. After successfully completing this seminar, participants will be able to apply Lean manufacturing appropriately to their own companies. Who should attend? This course is designed for: Manufacturing and Operations managers, production supervisors, project teams, material planners, maintenance staff, purchasing professionals and hands-on line staff, functioning in key areas including, quality engineering, supplier management, cost accounting, consultants and anyone tasked with manufacturing improvements. Diverse types of industries in manufacturing environments including Electronics, Computers, Telecommunications, Medical Device, Healthcare, Fabricated Metal and Machining, Plastic, Chemical, Pharmaceutical, Food and Beverage, consumer goods manufacturers and others to enable them apply the best practices and leading tools and techniques of Lean to their processes in all functional areas. 2 Lean Manufacturing Training Course

3 Course Approach KPMG s training program for Lean Manufacturing Practitioners is conducted in a dynamic environment using interactive simulation, lectures, selected hands on exercises and quizzes including discussions of actual case studies of successful lean performance improvement, and the most current tools and techniques available. Many Lean manufacturing initiatives fail because people don t know where to start or how to sustain the improvements. KPMG s Lean Manufacturing Practitioner training program provides participants with a structured approach to initiating and managing Lean supply chains and processes across diverse manufacturing environments. By focusing on reducing waste and improving flow in manufacturing organizations, Lean manufacturing produces just what is needed, when it is needed with no additional labour, costs or time, resulting in bottom line savings. KPMG s Lean Manufacturing Practitioner Course Outline Key Learning objectives and outcomes Lean manufacturing concepts The philosophy of Lean Manufacturing The science of Lean Manufacturing Bottom line benefits Common misconceptions of lean Understanding versus imitating lean organizations Value stream mapping Spaghetti diagrams Operational stability Minimal cycle time Identification and elimination of waste Robust product and process design Supplier involvement Visual factory Level, sequential production (Heijunka) Lean supply chain management A ten-point roadmap Manufacturing as a management strategy Handling resistance Lean Production flow Goals and performance measures Assessing today s factory Reducing lead time Continual Improvement Kaizen events Point of Use Logistics Reducing inventory Total productive maintenance Standardized work Continuous material flow Pull production control Mistake-proofing Leading change Avoiding common traps 5S+S Philosophy Rapid improvement Lean Manufacturing Training Course 3

4 Training Program Schedule DAY 1 1. Introduction to Lean Manufacturing / Lean Principles Introduction to Lean History of Lean Lean thinking Goals of Lean manufacturing strategy The Toyota Productions System (TPS) Introduction to Six Sigma DMAIC and Lean The five (5) lean principles The Lean culture Lean concepts and its goals Understanding eight (8) Wastes Manufacturing The building blocks of Lean Manufacturing 2. Introduction to Lean Manufacturing tools Lean as a total system and the phases of lean Planning and assessment, Value Stream Mapping Hoshin planning, PDCA, A3, Kaizen Cause and Effect Diagram, FMEA Stability, 5S, Visual Controls, Standardized work Total Productive Maintenance, Poka Yoke Continuous Flow, Kanban, Point of Use Work Station Design, Cellular Flow Synchronous Flow, Multiple Value Streams Batch Size Reduction, Quick Changeover, SMED TAKT-based Production, Supermarkets, Factory Floor Layout Production Leveling, Pull systems, Heijunka Every Product Every Day, Make to Order OEE Lean Maintenance SIPOC Manufacturing Resource Planning (MRP) DAY 2 3. Produce Only as Needed Value Stream Mapping to improve operation efficiency Reducing production lead time Small lot, mixed and level production Pull production control 4. The Need for Process Improvement & Standardisation Facilities layout for efficiency and flexibility Cellular manufacturing with small, flexible machines Synchronising and balancing processes Multi machine operation Autonomation Standard Operation 5. Problem Solving, Error Proofing & Supporting Techniques for Lean Graphical problem solving tools Using basic lean problem solving tools and techniques Plan, Do Check, Act (PDCA) problem solving approach 5S Workplace organisation Visual management techniques TPM maintaining and improving equipment Set-up Time Reduction to improving Machine Uptime Target zero defect through poka-yoke Inventory reduction 4 Lean Manufacturing Training Course

5 DAY 3 6. Extend Lean Suppliers and Customers Invest in suppliers and engage customers Supplier selection and relationship Supplier location and delivery schedule Lean Leadership & Implementation How to deploy Lean in an organization How Lean links with Six Sigma DMAIC How to develop Lean Leadership Facilitation for Lean Change Management in a Lean environment KPI s measuring success Quantifying the benefits of Lean Building a Lean team Lean Culture and what it means Simulation to show the benefits of Lean and how to use them Invest in People Teamwork Multi-skill workforce Small-group improvement activities Upon successful completion of the training and passing on open book exam, the delegates will be awarded certificates of completion in Lean Manufacturing Practitioner. Lean Manufacturing Training Course 5

6 Course Facilitator s Profile Joseph P. Muga This interactive workshop cutting across various sectors and manufacturing processes will be facilitated by Joseph P. Muga, a Certified Lean Six Sigma Master Black Belt with over 25 years global experience with KPMG Internationally in Los Angeles, USA and currently as an Associate Director in KPMG East Africa. He has worked with some of the world s major manufacturing and service companies where he has trained and implemented Lean and Lean Six Sigma transformation strategies. His lean six sigma implementation and training experience spans global companies such as Honda, GE, Mitsubishi, Sanyo, Pentel, Tobutsu, Hitachi, Boeing, Apple, Samsung, Panasonic, Yamaha, Verizon, Nestle, American Hospital Supplies, Burlington Northern/Santa Fe Railways, Bank of America and many others. Other qualifications include Bs. Industrial Engineering, MBA, PhD in International Business & Developmental Economics, Certified in Production and Inventory Management (CPIM), Certified Trainer by APICS and adjunct Professor of Lean Six Sigma and JIT/TPS, California State University. Venue: Serena Hotel, Nairobi Dates: Lean Manufacturing Practitioner Training: August, 2015 Time: 8.30 am pm Course fees: Kshs. 65,000 (inclusive of VAT, meals and Course materials) For more information and registration contact: Catherine Mutuma Tel: Mobile: [email protected] Or: Purity Mutuku Tel: Mobile: [email protected] Visit our website: KPMG Kenya 8th Floor, ABC Towers Waiyaki Way P O Box 40612, GPO Nairobi, Kenya 6 Lean Manufacturing Training Course

7 kpmg.com/eastafrica Follow 2015 KPMG Kenya, a registered partnership and a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative ( KPMG International ), a Swiss entity. All rights reserved.