Principles of Lean Manufacturing
This introduction to lean provides a systematic approach to eliminating waste in manufacturing processes. Learn how to eliminate the eight forms of waste, use the 5S approach to organization, reduce batch sizes, utilize point of use storage, use pull systems, implement cellular/flow and implement quality at the source — and involve employees in the process. Live simulations provide realistic before-and-after scenarios.
Value Stream Mapping and Cellular Flow Manufacturing
Value Stream Mapping (VSM) is a method used to visually depict material and information flow through an operation. Learn the principles and techniques of the VSM process and draw a map of the current state of a sample company, apply lean concepts to develop an improved future state, draw it and identify the next steps needed to achieve the future state. Leave with the ability to map real work processes. This session includes both shop floor VSM and administrative VSM examples and discussion.
When processes are balanced, the product flows continuously and customer demands are easily met. Cellular/Flow Manufacturing links manual and machine operations into the most efficient combination of resources to maximize value-added content while minimizing waste. This workshop is enhanced with an emphasis on standardized work and work balancing.
Leading a Lean Culture / Project Management Tools
A crucial element for success in the transformation to lean is developing a lean culture. Many individuals charged with being the lean champion for their company may not have a background in leadership, which creates a challenge when launching the initiatives. The culture is the glue that holds the tools together and gets all employees involved. This session will look at the elements of developing a lean culture and methods for moving an organization forward on this journey. The topics covered include: understanding lean and a lean culture, leadership skills for the lean leader, personal and interpersonal effectiveness, team development, and organizational change and measures of success.
The 5S System and Quick Changeover
The principles of 5S are based on the simple idea that manufacturing improvements begin with a workplace that is organized, clean and standardized and contains only what is required. Attendees will discover how to enhance organizational communication and productivity, and learn how to employ 5S methods and implement visual workplace techniques in their operations.
Quick Changeover builds on the principles of the Single Minute Exchange of Dies (SMED) system to dramatically reduce or eliminate changeover time. The four-step Changeover Improvement Process is used to help companies design no-cost/low-cost solutions to reduce changeover time.
A. Total Productive Maintenance (TPM)
Reducing inventory imposes a need to maximize equipment productivity. Learn to analyze overall equipment effectiveness to determine how much equipment time is being used effectively. Find out why machine operators are the first resource for maintenance; and consider effective, preventive, and predictive maintenance tools that help reduce machine
downtime and achieve autonomous maintenance.
B. Project Design
Performance measures, project scoping & design
MENTORING WORK / PROJECT
On-site Project Implementation and Mentoring - Mentors to be assigned by topic/geographic considerations
This one-on-one involvement with the UW-Stout Manufacturing Outreach Center's Project Manager(s) is what makes our certificate program truly complete. After completing the workshops, attendees will have the necessary background to identify waste and set improvement plans in motion for their organization. The project is your opportunity to apply one of the lean tools presented in the certificate series to a specific area of need in your business. This is an integral part of the program as it allows attendees to apply what they have learned. At the same time, the lean project will bring immediate benefits to your company.
Project Report Out / Peer Review
This wrap-up session gives attendees the opportunity to present their projects and gain feedback from their peers and the lean experts, and benefit from discussion on best practices. Each participant will be given an opportunity to share their implementation project, ask for advice and receive feedback in an open forum. This day will provide you with a truly rewarding experience.
NEW! Participants are invited to bring up to 2 individuals from their owner/management group to participate in the final day of the program. These individuals will benefit from hearing the report-out you provide for your project and also hearing the presentations delivered by the other participants. (notification of additional attendees required.)