Lean Manufacturing

Introduction

With the increase in global competition, LEAN concept is introduced with the focus on reducing the Non Value Added (NVA) wastes for process improvement. Waste is anything that impedes the flow of the product as it is being transformed in the value chain. To maximize the efficiency of manufacturing/ services, we will share the practices/ tools from LEAN that can be used for continuous improvement towards operational efficiency/ excellence.

Course Objectives

Upon completion of this program, participants will be able to:

• Understand the basic concept of Lean Manufacturing
• Recognzie the seven wastes at the workplace
• Adopt the relevant Lean practices/ tools to identify opportunities for operational excellence
• Engaging management in Lean Manufacturing

Key Content

Module 1: Lean

• What is lean?
• 2 pillars of lean
  • JIT (Just in Time
  • JIDOKA (Automation)
• Apply lean concept in manufacturing and/ or service sectors
• Determine the benefits of Lean transformation

Module 2: Waste Identification

• 7 'deadly' wastes
  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Over processing
  • Over production
  • Defects
• Determine value added/ non value added

Module 3: Kaizen Methodology

• What is Kaizen?
• Kaizen activity cycle

Module 4: Lean Practices/ Tools

• 5S
• 7QC Tools
• Severtity
• Occurrence
• Detection
  Failure Mode Effects Analysis (FMEA)

Module 5: Building Lean Culture

• Create buy in from management and staff level
• Link Lean initiatives to departmental goals
• Measure effectiveness of Lean initiatives