The goal of this program is to build a stronger internal support team with the knowledge,
skill, and ability to assess existing operations, to develop highly effective lean
restructuring plans or facility layouts, to develop strong supporting systems, such
as internal logistics or production control systems, and to lead teams to execute
The specific content of this 2-week workshop will be tailored to meet your team’s
specific needs. An example curriculum follows:
Week 1 - Lean System Design 1
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 Ssystems. 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.
Week 2 - Lean System Design 2
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
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.
This program is designed for teams of experienced lean specialists. This is appropriate
for your corporate lean team, six sigma black belts, or specialized tiger teams
assigned to the most pressing problems an organization faces.
We conduct this workshop only onsite for individual companies. It is often conducted
with two or three rapid improvement events to rapidly bring change agent skills up to a high level. This
workshop requires no special facilities. The ideal meeting space is approximately
30’ x 30’.