Introduction to Basics of Lean Management

Identify defects as the first act of waste and learn to add value by doing it right first time, reducing rework through visual controls, standard operating procedures, and mistake proofing.

Identify transportation waste as unnecessary movement of people, material, or information, and reduce it by minimizing physical distance with zoning, better layouts, cellular layouts, and visual control tools.

Eliminate over processing waste by removing features the customer does not need or will not pay for. Use value stream mapping to differentiate value adding from non-value adding activities.

Discover how lean philosophy targets the eight types of waste to eliminate non-value-added steps, continuously improve processes, and use lean tools in concert to increase customer value.

Explore lean tools such as 5s, poka-yoke, just in time, kanban, and smed to reduce waste, enable continuous improvement, and improve overall equipment effectiveness and tpm.

Explore standard operating procedures to standardize pen production, establish operational definitions, and communicate via visuals to ensure consistent quality and continuous improvement.

Explore total productive maintenance (TPM) as a program to boost production, morale, and job satisfaction. Review maintenance types: breakdown, preventive, periodic, predictive, time-based, corrective, and maintenance prevention, and minimize downtime.

Explore the purpose and types of mistake proofing (poka-yoke) and its benefits. See real-world examples like elevator sensors, room key holders, and parking brake shutdown.

Introduce kaizen as a company-wide approach to continuous improvement, where all employees collaborate to achieve regular incremental improvements in the manufacturing process, leveraging collective talent for change for good.

Review lean tools for waste elimination and raise awareness of five s, visual management, and sops. Highlight tpm, poka-yoke, smed, kanban, kaizen, and one-piece flow to drive continuous improvement.

Learn to map existing business processes with high-level maps such as IP Ossi maps or C-PAC maps, mid-level and value stream maps, to explain a process or identify a problem.

Learn to use SIPOC maps to outline high-level processes, identify suppliers, inputs, process steps, outputs, and customers, and drill down into mid-level and detailed maps while ensuring linkage across levels.

Learn takt time, a lean concept calculated as available work time per day divided by customer demand per day, with two components: available work time and units to be produced.