Day 1
1. Review Participant Expectations and Experiences with Lean
2. Philosophy of Lean
3. The Eight Non Value Added Activities
4. Value Stream Mapping
- Emergency Room Example
5. Time Study & Spaghetti Diagrams
6. Non-Lean Simulation
- Vehicle Factory or Truck Dealership
7. Workshop Exercise : Create Value Stream Map & Spaghetti Diagram of the Vehicle Factory or Car Dealership
8. 5S Visual Management
9. 5S Project Planning
- Team, Scope, Timeline, Benefits
10. 5S – Sort, Set-In-Order, Shine
- Implement the first 3 S’s on the Vehicle Factory or Truck Dealership
11. 5S – Standardization: Visual Standardization Tools
- Visual Safety Requirements, Visual Scheduling Boards, 5S Audit Poster, Set-In-Order Bulletin Boards
12. 5S – Standardization: Visual Work Instructions
- Create Visual Work Instructions for Vehicle Production or Car Dealership Sales
13. 5S – Sustain
- Random 5S Audits
- Renewing 5S (Re-5S.
- The 5S Implementation Schedule
14. 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
15. Process Flow Mapping
- Identify and Eliminate Non Value Added in Business Processes
16. Defining the Customer
- Internal, External, General Public
17. Creating the Current State Process Flow Map
- Mapping Methods (Shapes, Colors, Connectors, Materials.
18. Process Sorting
- Color Coding Each Task, Document and Decision
19.Eliminating Non Value Added Steps
- Master Red Tag List
- Issues and Ideas
20. Prioritizing Ideas
- High Benefit and Easy to Implement
21. Turn Ideas into Action Plans
22. Quantify Time Savings
23. Future State Process Flow Map
24. Quickchangeover
- Improving Asset Utilization
25. Internal and External Elements of a Changeover
26. Quickchangeover Time Study Method
- Car Racing Pit Crews as the Benchmark
27. Analyzing the Time Study Data
- Eliminate Non Value Added Steps
- Make External Steps External
- Move Internal to External
28. 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