Introduction to Lean and Factory Simulation: History of Lean and comparison to other methods - The 7 Wastes, their causes and the effects - An overview of Lean Principles / concepts / tools - Stockless Production.
The Tools of Lean Manufacturing: Continuous Flow - Continuous Flow Manufacturing and Standard Work Flow - 5S and Pull Systems (Kanban and ConWIP systems) - Error Proofing and Set-up Reduction – Total Productive Maintenance (TPM) - Kaizen Event examples. Toyota production systems, Ford production systems
Value Stream Mapping – Current state: Preparation for building a Current State Value Stream Map - Building a Current State Map (principles, concepts, loops, and methodology) - Application to the factory Simulation scenario.
Value Stream Mapping – Future State: Key issues in building the Future State Map - Process tips in building the map and analysis of the customer loop, supplier loop, manufacturing loop and information loop - Example of completed Future State Maps - Application to factory simulation – Implementation of lean practices - Best Practices in Lean Manufacturing.