LEAN MANUFACTURING AND TRAINING

Lean: Our approach to lean manufacturing and product design employs the principles of the Toyota Production System, TPS, developed by Taiichi Ohno, president of Toyota (Gosei).

Benefits of Lean:

• Throughput: + 40 --> 80%
• Manufacturing Lead Time: - 50 --> 90%
• Work-in-Process: - 60 --> 80%
• First-Pass Yield: + 50 --> 100%
• Floor Space: - 5 --> 50%
• Capitalization cost: - 50%
• On-time Delivery: +99%
• Administrative Cycle Time: - 50 - 90%

Tools and Training:

• Employee Involvement: We use a people-centric, learn by doing, and training, team based approach that evolves into self-directed teams
• Enterprise-wide Value Stream Mapping: Time-based value add, VA/VE analyses
• TOC, Theory of Constraint Analyses: To find the organization’s fundamental constraint or conflict and solve it in a ‘Win- Win’ way
• Balanced ‘Smoothed Flow: Controlling the input, minimize over/under production
• Kanban Design: What, when, how much to produce
• Work Cells Design, Single Piece Flow, Factory Layout: Keep things moving
• SMED: Single minute die exchange; Maximize throughput, minimize work-in- process, mixed model builds, short lead time deliveries
• Scheduling: HMLV, High Mix Low Volume production
• Six Sigma: Problem solving and process/product design
• TPM: Total Production Maintenance
• Five-S

Course Formats:

• On-site, customer training or
• Web-cast TRIZ training
  1. - 2.1: Intensive, one day (8 hour) six sigma quality training
  2. - 2.2: Extended, eight, one hour sessions

Handouts:

1. Course: notes, problems and solutions
2. Problem solving templates