Lean Mastery

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Lean Enterprise Training from Gatlin International is Ideal for Anyone Involved in Management

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Description

Gatlin International offers lean enterprise training for individuals and organizations looking to increase productivity and efficiency and eliminate waste in their business processes. Lean Enterprise is a proven process designed to bring about rapid improvements to the performance of any organization through a comprehensive overhaul of the value stream. Lean enterprise consists of a comprehensive set of rules, tools and elements that focus on enhancing value, eliminating waste and ongoing, incremental improvement.

Businesses of all kinds and sizes need to focus on waste-free processes in order to grow their profit margins and remain viable in the competitive landscape of the global economy.

The Lean enterprise process focuses on the elimination of waste from all business activities which is achieved through the implementation of concepts that provide high quality products, delivered in a timely manner, at the lowest possible cost in direct correlation to specific customer demands.

Companies that have transitioned to a Lean enterprise culture have seen dramatic improvements in a variety of areas including profitability, customer service levels, productivity, asset management, liquidity, inventory levels, changeover times, product design, overall quality, cycle times and lower product costs.

Lean Mastery is predicated upon clear, concise information on transforming an enterprise to a Lean enterprise. Our Lean enterprise course is packed with real world examples, photographs, graphics, quizzes, progress evaluations, case studies and a host of interactive features that provide tips, exercises and comprehensive information. The Lean enterprise program contains 60 hours of study that covers all of the Lean Enterprise concepts and was authored by a team of experts with hands-on, practical experience.

Upon registering in our Lean Enterprise course you are given an initial six months to complete the program. Should you need more time, you may request a 6-month extension at no additional charge.

Course Objectives

Upon completion of the Lean Enterprise course, the student will have gained a broad understanding of Lean Enterprise concepts and the interaction between the Lean elements, rules, and tools. They will also understand how Lean Enterprise concepts can be applied to the different operational departments of a business and why the corporate culture must change in order to maximize the Lean process. Studenst will recognize how the application of Lean Enterprise principles can substantially improve the operating and financial health of any business and will understand how to recognize and eliminate waste. Successful candidates will know how to identiry value added, non-valued-added and non-value-added-but-required activities within the organization. They will also understand why every stakeholder in the organization must participate in the Lean process and how this can be accomplished. Upon completion of the Lean Enterprise course you will know the importance of identifying the value stream, how it is mapped and how to identify areas that require improvement. You will also gain a thorough understanding of the elements of Flow and Pull and how these concepts are applied within the organization and you will learn why the pursuit of perfection is a way of life. You will also understand the fundamentals of Standard Work and how these fundamentals can be used to help eliminate process variations and you will be able to recognize why the limit-people-and-materials rules are integrated with the lean tools to eliminate waste. Other core concepts you will learn include understanding how to develop a road map and an implementation plan, understand Policy Deployment and why this is a critical part of any Lean implementation process and how to recognize the fundamental importance of the Kaizen process and how this is used in every aspect of a Lean implementation and how it is used to change the culture.

Other course objectives include learning about the concept of Design for Manufacture and Assembly and how design influences cost and gaining a broad understanding of the concepts of 5S, Single Minute Exchange of Dies (Quick Change), Total Productive Maintenance (TPM), Kanban, Visual Workplace, Error-Proofing and Scheduling.

Finally, you will understand the role of accounting in the Lean Enterprise implementation process and how lean metrics replace traditional metrics. You will also learn how metrics drive behavior and how cost of quality impacts business performance.

Our Lean Enterprise course also provides an overview of Six-Sigma and how Lean Enterprise and Six-Sigma are used in tandem to improve business performance.

Outline

I. Foreword

  1. Lean Enterprise Defined
  2. How It All Began

II. The Need for Change
  1. Why Change?
  2. Benefits of Lean
  3. The Evolution to Lean
  4. Touring a Traditional Operation
  5. Lean v. Traditional Manufacturing
  6. Batch and Queue
  7. The Role of Management
  8. Organization Changes
  9. Resistance
  10. The Role of Education

III. Lean Theory
  1. Overview
  2. Waste
  3. The Types of Waste
  4. Provide Value
  5. Radical Change
  6. Continuous Incremental Improvement
  7. Lean Elements
    1. Value
    2. Value Stream
    3. Flow
    4. Pull
    5. Perfection
  8. Lean Rules
    1. Standard Work
    2. Limit Material Movement
    3. Limit People Movement
    4. Educate Everyone
  9. Lean Tools Overview
    1. Kaizen
    2. 5S
    3. TPM
    4. SMED
    5. Process Mapping
    6. Takt Time
    7. Line/Work Balancing
    8. Kanban
    9. Mistake Proofing
    10. Autonomation
    11. DFMA
    12. Visual Workplace
    13. 5 Why
    14. One-Piece-Flow
    15. Spider Charts
    16. Spaghetti Charts
    17. U-Shaped/Continuous Flow Cells
    18. Rabbit Chase
    19. Six Sigma
    20. Focused Factory

IV. Kaizen
  1. Kaizen Defined
  2. Philosophy
  3. 10 Principals
  4. Problem Selection
  5. Guidelines
  6. Value-Added, Non Value-Added, Non-Value-Added Required
  7. Manufacturing Kaizen
    1. Batch and Queue
    2. Manufacturing Kaizen goals
    3. Manufacturing Kaizen aspects
    4. Manufacturing Kaizen presentation
    5. Summary
  8. Administrative Kaizen

V. Value Stream Mapping
  1. VSM Defined
  2. Purpose of VSM
  3. Technology Used
  4. The Current State Map
  5. The Future State Map
  6. Strategy
  7. Getting Started
  8. The Team
  9. Developing a VSM
  10. VSM Approach
  11. Definitions and Icons

VI. Transforming the Enterprise

VII. SMED (Single Minute Exchange of Dies/Quick Change
  1. Audi
  2. Goals
  3. Traditional Concepts
  4. Inventory
  5. Benefits
  6. Rules
  7. Internal v. External Activities
  8. Methodology
  9. Observe and Document Current Process
  10. Separate Internals from Externals
  11. Develop Plan
  12. Observe and Document New Process
  13. Standardize New Process
  14. Celebrate

VIII. TPM (Total Productive Maintenance
  1. Introduction
  2. Definition
  3. Alternatives
  4. Prevention Principles
  5. Obstacles
  6. Types of Breakdowns
  7. Deterioration
  8. How TPM is Implemented
  9. Overall Equipment Effectiveness (OEE)
  10. Calculating OEE
  11. The Six Big Losses
  12. Types of Maintenance
    1. Preventive
    2. Breakdown
    3. Corrective
    4. Predictive
    5. Maintenance Prevention
  13. TPM Tools
  14. Autonomous Maintenance
  15. 7 Steps to Autonomous Maintenance
  16. Skills Training
  17. TPM Strategy

IX. 5S
  1. Introduction
  2. Definition
  3. Separate
  4. Sort
  5. Sweep
  6. Standardize
  7. Sustain
  8. Safety

X. DFMA (Design for Manufacture and Assembly
  1. Definition
  2. Traditional Approach
  3. Concurrent Engineering
  4. DFMA Principles
  5. DFMA Rules
  6. Why DFMA?
  7. Design Techniques
  8. Design Process
  9. Design for Six Sigma Overview
  10. DFMA Benefits
  11. Product Release

XI. Kanban
  1. Introduction
  2. Definition
  3. Pull v. Push Systems
  4. Function
  5. Applications
  6. Information Flow
  7. Types
  8. Calculations
  9. Information Requirements
  10. Manufacturing Rules
  11. Planner Rules
  12. The Role of MRP
  13. Electronic Systems
  14. Inventory Carrying Costs

XII. Other Lean Tools
  1. Standard Work
  2. Visual Workplace Management
  3. Error Proofing (Poka-Yoke)
  4. Scheduling and Leveling (Heijunka)
  5. Value Selling

XIII. Lean and Six Sigma Overview

XIV. Lean Accounting Overview

XV. Implementing Lean
  1. Putting it All Together
  2. Lean Road Map
  3. Policy Development
  4. Lean Implementation Plan
  5. Lean Metrics

Demo

Click here to view a demo of this class.

Additional Info

Languages
English
Course Length
60.00 hours
Duration of Access
6 months
Instructor
Brian Furlong
Prerequisites/Audience
There are no specific prerequisites for our Lean Enterprise course. The intended audience is executives, managers, supervisors, professionals and anyone who needs to learn how to substantially improve business performance.
Requirements/Materials Included
The Lean Enerprise course is compatible with the Windows Vista operating system.

The most commonly used forms will be available for download in Microsoft Excel format. Many of these forms are interactive and will perform calculations or build charts to be used in presentations. If students do not have Excel on their computer, a free download for an Excel viewer will be provided.

Provider Locator

Country: United Kingdom
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