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Advanced Lean Systems Design
 This program is designed for a team of experienced lean specialists, for example, a corporate team of lean coaches who lead transformation activities across the organization or a team of production, operations management, and business specialists charged with formulating an internal production system for your organization. It brings the gamut of ILS experience and expertise to the table, based on years of applied research, extensive engagement in lean transformation activities across a wide range of industries and service organizations, direct partnership with Toyota, development of 18 semester credit hours of academic instruction in lean systems, and our highly regarded “boot camp” approach. The goal of this program is to help you build a strong internal support team to have the knowledge to assess existing operations, to lead efforts to develop highly effective lean restructuring plans and supporting facility layouts, and to develop strong supporting systems, such as internal logistics and production control systems for those operations.
The specific content of this course would be tailored to meet your team’s specific needs. An example curriculum, based on two courses of instruction held over 10 days is shown below.
Course 1. Lean System Design 1. 5 days. Topics are as follows:
- The lean operational model. Explains the structural requirements of lean operation and explains proper integration of lean technical, managerial, and human systems through a series of hands on simulations. This knowledge is foundational to successful operations restructuring efforts.
- Survey of Basic Lean Tools. A brief review lean tools including 5S, visual control, setup reduction, standardized work, and source quality, emphasizing their role in operations restructuring. Assumes prior knowledge of each participant.
- Pull production control systems. This covers the theory, functionality, and implementation of pull production control systems. All standard types of pull systems are covered along with CONWIP, an alternative pull strategy useful in higher variability systems. Theory and operational aspects of all systems are demonstrated through hands-on, discovery learning simulations and system design exercises. Additionally, the use of visual control boards for flexible job dispatching, pull/scheduling interfacing, and supporting logistics systems are covered in detail. Leveling algorithms and buffer sizing calculations are covered.
- Value stream mapping. This covers value stream mapping as a tool for planning overall restructuring efforts. The treatment, which is far deeper than Learning to See, addresses basic product family and value stream definition, mapping conventions, executing VSM events, current state mapping, and future state mapping. Issues such as cell formation, strategic use of parallel structures, kitting and kitted flow, structures to improve system-level synchronization of material flows, realistic capacity calculations, design of buffering systems, and detailed integration of production control and logistics systems are covered in depth. Students execute a complex, detailed case study with a model factory (based on real world factories we have restructured) to learn how to apply this important tool in detail. The case study requires determination of cells, detailed address of necessary supporting kaizen activities, production control design, capacity analysis, proper dealing with monument operations, consideration of alternative pacemaker locations, and various production control and scheduling design issues.
Course 2. Lean System Design 2. 5 days. Topics are as follows:
- Extended enterprise-level restructuring. Value stream mapping concepts from Course 1 are extended to the extended enterprise level, including supporting operation such as engineer-to-order and supply chain/logistics structuring. A case study involving restructuring of an integrated sales, design-to-order, component procurement, scheduling, and manufacturing case is executed by the students, extending their learning from the previous class to the total enterprise level where white collar processes and transactional systems are important. This case also addresses elimination of waste in information flow processes and addresses financial performance measurement in a lean system.
- Production flow analysis. The use of this tool for defining parts families in complex high variety/low volume situations is addressed in detail, including case studies.
- Detailed design of lines, work cells and support systems. This addresses issues such as workstation design, internal material handling, systematic layout planning, external logistics support, the use of strategies such as minomi and kitting, line balance, and flex work systems that are useful in improving work balance in complex systems with high work content and demand variability. Hands on exercises and simulations are used extensively.
- Waste and Factory Physics. A very in-depth treatment of waste that develops a sophisticated eye for identifying and eliminating it. This treatment incorporates factory physics concepts and illustrates major concepts through real world cases that the teachers have encountered in their professional practice.
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ILS Training Modules
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