American Management Association Seminars
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Lean Manufacturing: Doing More And More With Less And Less
Seminar No: 04502 -XNBB
CEU Credits: 1.8
Length: 3 days
Today, more than ever, you have to trim the fat in your operations.
Learn how to turn operations into an effective tool to compete in today's marketplace by becoming faster and more responsive to customer demand! Help your company do more--more rapidly--with fewer resources, less risk, less investment and less effort.
Presidents and CEOs, VPs and directors of manufacturing and operations, general managers, plant managers, manufacturing and industrial managers, supervisors and engineers, design and process improvement engineers and procurement and materials managers.
How You Will Benefit:
- Cut manufacturing lead time from weeks to days to hours
- Reduce the inventory, equipment and facilities required to manufacture
- Enhance plant reliability and availability
- Improve production control with a minimum of scheduling
- Give customers what they want more quickly
- Increase worker involvement in, and commitment to, eliminating defects and improving productivity
What You Will Cover:
- How to eliminate waste...reduce lot-size...and cut inventory
- Applying cellular manufacturing for improved work flow
- Cultural and organizational issues
- Using mass customization to rapidly respond to customers
- Aligning suppliers to support your effort
Extended Seminar Description
Why Lean Manufacturing?
- Cut Manufacturing Lead Time from Weeks to Days to Hours—and Increase Responsiveness to Customer Requirements
- Reduce the Inventory, Equipment, and Facilities Required to Manufacture
- Enhance Plant Reliability and Availability Simultaneously
- Improve Production Control with a Minimum of Scheduling
- Give Customers What They Want More Quickly
- Increase Worker Involvement and Commitment to Eliminating Defects and Improving Product Quality
Improving the Manufacturing Shop Floor; Leaning up Inventory and Reducing Setup Time
- Understand the Concept of Speed in the Marketplace and How Lean Manufacturing Enables a Manufacturing Company to Compete Using Speed
- Recognize Lean Manufacturing Methods That Successful Companies Have Used to Satisfy Customers and Grow Market Share
- Be Able to Create Process Flow Diagrams of Your Own Company Which Will Indicate Opportunities for the Application of Lean Manufacturing Methods
- Gain Knowledge of the Detailed Tactics of Lean Manufacturing and How They Fit into Its Overall Goals of Attracting Customers and Beating Competitors with Rapid Response Capabilities
Building a Cellular Manufacturing Base for Lean Manufacturing: Emphasizing Flows
- Gain a Tactical Orientation of a Production Shop Floor, with a Set of Actions You Can Take to Begin Using Lean Manufacturing in Your Company
- Acquire the Ability to Distinquish Value-Added Actions and Practices from Non-Value-Added
- Become Aware of the Detrimental Effects of Raw Stock, Work in Process, and Finished Goods Inventory on the Ability of Your Company to Build What Is Currently Selling
- Identify Opportunities for Waste Elimination in Your Own Company
- Implement Setup Time Reduction Techniques on Many Varieties of Equipment
- Understand How to Drop Lot Sizes in Your Own Factory in Order to Gain Speed of Response to Customers
Identify Potential Traps That Companies Encounter as They Attempt to Begin Implementing Lean Manufacturing
Lean Manufacturing Methods Which Cause Work to Be Correctly Executed: Quality on the Shop Floor
- Comprehend the Problems with Traditional Departmental Layouts
- Discuss the Disadvantage of Push Systems Versus Pull for the Movement of Materials
- Attack Confusing Material and Information Movements in Your Company through the Use of Visual Controls
- Build and Utilize Workcells and Flow Layouts in Order to Gain Visibility and Simple Controllability of Processes in Your Own Company
- Configure Your Factory So That Increased Output Is Attainable in Decreased Amounts of Space
- Evaluate Equipment and Its Appropriateness to a Lean Manufacturing Plant
- Improve the Flows of Materials in Your Own Company by Making Them More Self-Controlling
- Improve the Flows of Information in Your Own Company by Making Them Self-Evident
- Address Your Own Company to Drastically Reduce Lead Times, Cycle Times, and Overall Response Time to Customers
Organizational and Cultural Issues for Lean Manufacturing Companies
- Organize Your Company’s Quality Efforts towards the Simultaneous Achievement of Higher Quality and Faster Response Time
- Understand Traditional Quality Methods and Why They Fail in the Face of Tough Competition
- Apply the Logic of Lean Manufacturing Quality Methods to Your Company’s Products and Processes, Leading to a Steadily Improving Quality and Speed of Response to the Market
- Implement a Series of Successively More Powerful Quality Mechanisms towards a Goal of Zero-Defects
- Approach Machinery Preventive Maintenance as an Enabler of Rapid Response to Customers, and Apply the Logic of Quick Changeovers to PM Procedures
Aligning Supplier and Material Flows to the Shop Floor
- Understand the Pressures Placed on an Organization and the People within It by the Use of Lean Manufacturing Methods
- See How Position Descriptions Radically Change within a Lean Manufacturer
- Understand How Management’s Role Changes Significantly as a Result of Lean Manufacturing
- Apply Several Organizing Approaches to Your Own Company to Take Full Advantage of Lean Manufacturing
- Gain the Ability to Attack Counterproductive Pay and Reward Practices and Create More Useful Ones
Product Design for Lean Manufacturing
- Manage a Supplybase to the Best Advantage for Lean Manufacturing Companies
- Recognize the Key Attributes to Seek Out in Suppliers for the Best Performance of a Lean Manufacturer
- Drastically Reduce the Paperwork Burden Necessary to Move Materials Rapidly to Where They Are Needed
- Understand the State-of-the-Art Methods for Closely Connecting Suppliers and Customers in Support of Lean Manufacturing
- Construct Relationships with Suppliers Based on Both Tightly and Loosely Established Agreements
- Gain the Ability to Select for Your Own Company the Most Useful Material Movement Methods, Streamlining Delivery and Transportation Techniques
Going Lean with Production Planning, Scheduling, and Control
- Recognize How the Designs of Products and Their Supporting Processes Further Enhance Lean Manufacturing and the Ability to Rapidly Respond to Customers
- Understand How Modular Design Methods Allow Products to Move Quickly through the Production Process
- Attack Piece-Part-Intensive Designs and Find Opportunities for Simplifying Them, Thus Reducing the Burden of Assembly, Engineering, and Paperwork
- Compare Traditional Design Methods with Those That Allow Postponement, Thus Permitting Leaner Inventory Levels While Increasing Customer Service Levels
- Use Lean Manufacturing Approaches to Design Products and Processes Which Achieve Mass Customization in Some Industries
Money and Measurements for Lean Manufacturing
- Discover a Way to Simplify Operations to the Point Where Schedules Become Less Important as a Control Mechanism for Most Companies
- Compare Traditional Planning and Scheduling Methods with Lean Methods, and Discern the Advantages of Lean over Traditional
- Understand the Difference between Planning and Execution and How Companies Frequently Overlap and Confuse the Two
- Apply Replenishment and Planning Mechanisms Which Improve the Product Availability and Mix
- Reduce Data Collection and Manipulation in Your Own Company, without a Concurrent Loss of Control in the Factory
- Differentiate a Departmental Focus from a Process Focus, and Appreciate How Measurements Based on the Two Points of View Can Alter a Company’s Behavior
- Recognize How Employees Sometimes Spend More Effort on Non-Essential Work Than on What Is Essential to Current Demands. Based on This Recognition, You Will Be Able to Alter the Organization of Work So That People Exert Effort on the Items of Vital Interest to the Company
- Compare the Behaviors Elicited by Lean Manufacturing Oriented Measurements Versus Traditional Measurements, and Determine Which Would Be More Profitable and Effective in the Marketplace
- Judge the Appropriateness of a Narrowly Focused Improvement Effort in Your Company Versus a Company-Wide Effort
- Assess Your Company’s Measurements, Determine Their Usefulness, and Substitute Alternative Measures That Would Drive the Company In a More Competitive Direction
- Gain a Clear Understanding of the Sequences of Events That Your Company Will Traverse as It Initiates the Use of Lean Manufacturing Methods
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