Leading Manufacturing Excellence

Short course

In North East Lincolnshire

Price on request

Description

  • Type

    Short course

  • Location

    North east lincolnshire

This programme will give the participant a thorough grounding in Lean Manufacturing. It emphasises the importance of adopting a lean culture and provides a toolkit of the tools and techniques to successfully implement lean in your organisation. Suitable for: Middle Managers / Supervisors / Team Leaders / Senior Operatives

Facilities

Location

Start date

North East Lincolnshire (Humberside)
1-3 Dudley Street, Grimsby, DN31 2AW

Start date

On request

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Course programme

The course covers the following:

  • Manufacturing Excellence
  • 5S of Workplace Organisation
  • Process Analysis and Improvement
  • Problem Solving

Manufacturing Excellence

This module introduces the candidate to the principles of what lean manufacturing is and what it is trying to achieve. Initially it explains that the manufacturing process is a chain of customers, both internal and external and only by focusing on satisfying these customers can we ensure a world class manufacturing process.

It emphasises the importance of maximising value-adding processes whilst identifying and attacking every kind of waste. In doing so it explains the seven wastes as developed by Toyota Chief Engineer Taichi Ohno and Deming's 14 points.

The contrast between the traditional manufacturing approach and manufacturing excellence is discussed and lessons drawn.

There are numerous opportunities for the candidate to appraise the current level of lean manufacturing principles employed in their work environment as an indication of where their company is on the road to achieving Manufacturing Excellence.

This module also covers the importance of teamwork, team building and the different roles in a team. There is an interactive personal profile to determine which role in a team the candidate would be best suited for.

Finally the candidate is shown the performance targets that Lean Manufacturing aims to achieve, namely zero waste and rework, 100% on time delivery, zero setup times and so on. Performance figures of real life world class manufacturers such as Toyota and Motorola are used to show that whilst some of the goals are impossible to attain, through continuous improvement and using these goals as a target extremely impressive results such as 0.001% scrap and rework can be achieved. In contrast, the typical UK performance figures are worryingly poor.

Summary:

  • What is meant by Manufacturing Excellence
  • What do we need to focus on to attain Manufacturing Excellence?
  • Where are we, as an organisation on the road to Manufacturing Excellence?
  • Motivation
  • Implementing successful teams
  • What makes a successful team
  • Team development
  • Personal profile within a high performance team

5S of Workplace Organisation

Once the candidate has developed an appreciation for the need to employ lean manufacturing techniques, it is time to start arming them with the tools with which to achieve this. The first step in doing this is 5S. 5S comprises five principles (all of which original derive from Japanese words beginning with S) that if followed, will create a safe, clean and efficient workplace, not to mention a more pleasant one.

Before we can begin to improve the manufacturing processes themselves, the work environment has to be organised so as to help facilitate these improvements. The 5S module teaches the candidate the afore-mentioned five principles, their importance, and the techniques and tools with which to implement them.

There is an opportunity for the candidate to evaluate the current performance of their workplace as a start point from which to initiate improvements using the 5S techniques.

Some of the key outcomes of implementing 5S are improved safety, less downtime, faster changeover and set-up times, and reductions in stock, material, tool, labour and time wastage. A work environment based on 5S principles is flexible and able to respond quickly to problems or new production orders. Problems, abnormalities and waste can then be readily identified by anyone in the workplace, allowing for a quick and decisive resolution.

Summary:

  • Sort Through Sort Out

Establishing what is needed in the workplace and what is not needed in the workplace.

  • Set Limits and Locations

"A place for everything and everything in its place"
Determine location and quantities for all needed things.

  • Shine the Workplace and Equipment

Keeping the workplace immaculately clean. Using cleaning as a form of inspection. Exposing problems before they cause breakdown.

  • Share Information and Standards

Standardise everything and make standards visible so all exceptions and errors can be easily and immediately recognised by anyone.

  • Stick to the Rules

Correct procedures become a way of life, all training of employees is complete and people who actually work there monitor the workplace.

Process Analysis and Improvement

In this module the candidate will look at analysing and streamlining the production processes using a number of powerful techniques.

These include mapping the processes so that areas can be identified for improvement and the removal of bottlenecks. The inputs and outputs of the processes are examined with a view to reducing the amount of stock and the duration in which it is carried, bringing the arrival of stock closer to the time that it is used, saving time, money and space.

By mapping the numerous operations involved in the production of an item, it is possible to quantify the time and cost of the operations and to determine just how much time is being spent on adding value to a product, as opposed to the time wasted in non-value adding operations, such as storage and transit.

The end result is that the candidate will be able to analyse a production process and identify where improvements can be made to reduce stock, waste and lead times. Once implemented in the workplace this will lead to a leaner, more flexible, profitable and secure manufacturing company.

Summary:

  • Centre out method
  • Input / Output analysis
  • Process flow charting
  • Downtime analysis
  • Waste analysis
  • Cost reduction
  • Productivity improvements

Problem Solving

This module builds a framework of tried and tested procedures allowing the candidate to solve all manner of problems, from initial problem identification through to closure.

The procedures contained in this module include data collection, where data is collected and analysed and from which informed decisions can be made, and brainstorming in which you would use a structured and systematic approach to highlight all options and potential problem causes. This module also covers Pareto charting and fishbone diagrams and highlights the common faults in problem solving such as inadequate problem clarification, over-reaction or only treating the symptoms and not the root cause.

The module outlines the criteria of a good solution and explains how to decide which of several solutions is the most appropriate.

Summary:

  • What is a problem
  • Common mistakes when problem solving
  • Problem clarification
  • Brainstorming
  • Fish bone diagram / Cause and effect
  • Data collection
  • Pareto charting
  • Criteria of a good solution
  • Developing solutions

Duration:

2 Days (or 4 half day sessions)

Leading Manufacturing Excellence

Price on request