Lean Champion Workshop Outline – Day 1
- Review Participant Expectations and Experiences with Lean
- Philosophy of Lean
- The Eight Non Value Added Activities
- Value Stream Mapping
Emergency Room Example - Time Study & Spaghetti Diagrams
- Non-Lean Simulation
- Vehicle Factory or Truck Dealership
- Workshop Exercise : Create Value Stream Map & Spaghetti Diagram of the Vehicle Factory or Car Dealership
- 5S Visual Management
- 5S Project Planning
- Team, Scope, Timeline, Benefits
- 5S – Sort, Set-In-Order, Shine
- Implement the first 3 S’s on the Vehicle Factory or Truck Dealership
- 5S – Standardization: Visual Standardization Tools
- Visual Safety Requirements, Visual Scheduling Boards, 5S Audit Poster, Set-In-Order Bulletin Boards
- 5S – Standardization: Visual Work Instructions
- Create Visual Work Instructions for Vehicle Production or Car Dealership Sales
- 5S – Sustain
- Random 5S Audits
- Renewing 5S (Re-5S)
- The 5S Implementation Schedule
- Wrap-Up and Evaluation
- Your plan for Value Stream Mapping and 5S Implementation
- Lean Champion Workshop Outline – Day 2
- Teams present progress on their Lean Project’s Value Stream Map and photos of 5S Activities
Process Flow Mapping
Identify and Eliminate Non Value Added in Business Processes
Defining the Customer
Internal, External, General Public
Creating the Current State Process Flow Map
Mapping Methods (Shapes, Colors, Connectors, Materials)
Process Sorting
Color Coding Each Task, Document and Decision
Eliminating Non Value Added Steps
Master Red Tag List
Issues and Ideas
Prioritizing Ideas
High Benefit and Easy to Implement
Turn Ideas into Action Plans
Quantify Time Savings
Future State Process Flow Map
Quickchangeover
Improving Asset Utilization
Internal and External Elements of a Changeover
Quickchangeover Time Study Method
Car Racing Pit Crews as the Benchmark
Analyzing the Time Study Data
Eliminate Non Value Added Steps
Make External Steps External
Move Internal to External
- Wrap-Up and Evaluation
- Your plan for Value Stream Mapping and 5S Implementation
- Day Three – Kanban & Flow Processing
- Teams present the Current and Future State Process Flow Maps and/or Quickchangeover Analysis from their Lean Project.
- Kanban Materials Management
- Push Versus Pull
- Kanban Calculations
- Physical Organization of a Kanban System
- Two Bin, Multi-Bin or 1 Bin
- Workshop Exercise
- Implement Kanban on the Vehicle Factory Components or Truck Dealership’s Supplies
- Flow Velocity® Processing
- Details of Flow Systems
- Balancing Supplies, Labor and Work-In-Process
- Detailed Time Study & Spaghetti Diagrams
- Takt Time Calculation
- Theory of Constraints
- Product Families
- Flow Diagram / Flow Path
- Process Times
- Time Study Method
- Time Study Matrix
- Determine minimum number of time studies
- Workshop Exercise
- Perform Time Study of Vehicle Factory
- Flow Calculations
- Calculate Staffing
- Kanban Inventory Buffers
- Workshop Exercise
- Calculate the number of People Needed to Staff the Vehicle Factory
- Flow Balancing / Operational Definition
- Balance labor to enable continuous flow
- Flow Layout
- Cellular Production
- Workshop Exercise
- Design a One-piece Flow Cell for Vehicle Production or the Truck Dealership
- Balance Labor
- Balance Inventory
- Flow Layout
- Teams discuss the use of Flow Velocity® and Kanban for their projects.