Lean Work Cells and Lines

Lean work cells and lines are a key focus in restructuring operations for work flow. This course focuses on the design of these cells and the systems needed to support their effective operation. The training includes exercises where students design, implement, and operate realistic cells (e.g., mixed-model cells that assemble pneumatic regulators). This includes special attention to logistics support systems and live management strategies that implement the jidoka principle. Course duration is normally 4 days.

Students who take this class will learn…

• Production flow analysis as a practical procedure for product family identification in complex situations.
• Workstation design and workstation interfacing considering motion economy and human factors engineering
• Procedures for effective layout of the work cell
• Advanced cell structuring approaches useful in complex, high-variety applications
• Practical work design and line balance procedures to insure maximum labor efficiency
• Systems for team member engagement in improving line performance and productivity
• Systems that classify work content variability on mixed model lines and the use of this concept in designing more flexible and effective lines that are capable of absorbing this variability on a day-to-day basis and as product mix changes
• Design of several alternative flex-work systems that maximize line productivity and improve line performance under various conditions, including unpredictable work content variation
• Standardized work documentation systems, including effective systems for high variety operations
• Design of effective internal production control systems
• Design of material presentation and replenishment systems, including the design of part delivery systems and the use of kitting and minomi approaches
• The use of work-element standardization and element-based training systems as a basis for development of highly-skilled and flexible team members and enhancing quality control
• Procedures for building strong quality control systems into both design and operation of the line
• Principles and practices for effective live management of the cells and lines