Syllabus
Unit 1
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 – FPS gear model
Unit 2
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.
Unit 3
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.
