Lean Operations - Course Offerings

The training modules include:

Lean 101 - Principles of Manufacturing
Combined classroom and hands-on simulation of an operating factory in a 1-day, 8-hour course.

The first step to learning the principles of lean manufacturing.  No previous experience is required.  The course is a mix of classroom and live simulation.  Participants begin by manufacturing simulated circuit boards in a traditional forecasted manufacturing setting.  The results of the first simulation round will provide the basis for continuous improvement applying lean manufacturing principles.  Performance improvements are measured and compared for improved results. Click here to register for this class.

Lean 202 - Value-Stream Mapping
This course teaches how to map the current state of a product or process.  This is a two-day, 16 hour course with a field event.  This also can be a 1-day 8-hour course without the field event.

Learn how to create a map of an entire value stream.  This course teaches how to map the current state of a product or process.  Then with the current data determine the non value-added content and map out the proposed future state.  Participants will learn the steps necessary to eliminate waste in the system using the power of the value stream map to achieve an enhanced future state.  Real company examples and case studies are presented.  Participants will bring their own examples and create their own current and future state maps. Click here to register for this class.

Lean 203 - Visual Workplace/ 5S + 1
A combined classroom and hands-on simulation to enhance communication and productivity in a 1-day, 8-hour course.

This course will successfully teach how to transform a factory into a place where messages concerning product quality, productivity, schedule, and safety are accurately and rapidly delivered every day.  Participants learn methods to implement specific, easy to access, visual systems to enhance communication and productivity.  Course participants go away with knowledge of what visual order is and what the visual workplace looks like and how these concepts work on the production flow.  The course teaches how to deal with resistance, develop checklists, and use a process map to drive the process.  Examples are taken from case studies of successful companies are delivered. Click here to register for this class.

Lean 204 - Set-Up Reduction
A combined classroom and hands-on simulation to reduce set-up time by applying Single Minute Exchange of Dies (SMED) in a 1-day, 8-hour course.

This course teaches the fundamental principles of set-up reduction.  The instructor will clearly define set-up and discuss reasons and barriers to reducing set-up time.  The course follows the principles first expressed by Dr. Shigeo Shingo and his work in Single Minute Exchange of Dies (SMED).  Participants learn the standard methodology in applying SMED to any type set-up industry. Click here to register for this class.

Lean 205 - Cellular Flow Manufacturing
A combined classroom and hands-on simulation to link and balance operations, reduce lead times, minimize work in process, and optimize floor space in a 1-day, 8-hour course.

This hands-on course teaches how to link and balance manufacturing operations to reduce lead times, minimize work in process, optimize floor space usage, and improve productivity.  The instructor leads the class through the 5-step process for designing and implementing work cells. Click here to register for this class.

Lean 206 - Pull/Kanban Systems
A combined classroom and hands-on simulation to control shop floor inventory and production schedules in a 1-day, 8-hour course.

Students will learn how to control shop floor inventory and production schedules by implementing pull systems.  This course teaches how to design and implement a visually driven, employee controlled material replenishment system.  Participants also learn how to implement repetitive and non-repetitive pull systems, to set up point-of-use material storage, to interface with planning systems, and to balance lot sizes with capacity, not economic order quantity. Click here to register for this class.

Lean 207 - Total Productive Maintenance
A combined classroom and hands-on simulation to proactively maintain machines and equipmentat their peak productivity in a 1-day, 8 hour course.

This course offers the student a method to proactively maintain machines and equipment at their peak productivity.  Participants come away with an understanding of TPM and it's five major components.  Each student should understand how TPM increased overall equipment effectiveness and how it can help avoid interruptions to production.  The course provides a deep understanding of the seven steps to process maintenance. Click here to register for this class.

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