Topic outline

  • Process Lean/Optimization

    This course covers systematic techniques on process lean/optimization for managers, leaders, section heads, superintendents, supervisors, process engineers, production engineers, plant engineers and planning engineers.

    • Training Methodology & Objectives

      Training Methodology

      This Trainee-centered course includes the following training methodologies:-

      • Talking presentation Slides (PPT with audio)
      • Simulation & Animation
      • Exercises
      • Videos
      • Case Studies
      • Gamification (learning through games)
      • Quizzes, Pre-test & Post-test

      Course Objectives

      After completing the course, the employee will:-

      Apply and gain an in-depth knowledge on process lean/optimization Identify the lean manufacturing tools, the 8 lean tools and the 5 principles of lean manufacturing
      Discuss lean manufacturing PPT and apply lean techniques in manufacturing Describe FMEA as lean tool and ideas of lean as well as improve service quality
      Employ value stream mapping and recognize VSM commonly used symbols Review current and future state value stream map
      Apply lean process improvement techniques, floor layout analysis and process map and processing time value analysis Describe benefits Toyota production system (TPS), types of waste, lean and traditional manufacturing
      Identify the barriers to lean and implement lean including progress toward lean Discuss the 5 elements of 5S and employ elimination of waste and waste identification
      Brainstorm, analyze, implement, plan, execute, check and sustain Carryout the typical steps to complete a current state drawing as well as review typical results
      Implement change and determine the wrong ways to address roadblocks Explain the difficulties with human error and why existing tools are not enough
      Discuss the seven guidelines to Poka Yoke attainment including the Poka Yoke systems that govern the process Apply methods for using Poka Yoke, contact methods, counting method and motion-sequence method
      • Course Description

        This E-Learning course is designed to provide participants with a detailed and up-to-date overview of process lean/optimization. It covers the lean manufacturing tools, the 8 lean tools and the 5 principles of lean manufacturing; the lean manufacturing PPT and lean techniques in manufacturing; the FMEA as lean tool; the ideas of lean and improvement of service quality; the value stream mapping and VSM commonly used symbols; the current and future state value stream map; the lean process improvement techniques, floor layout analysis and process map and processing time value analysis; and the benefits Toyota production system (TPS)
        During this course, participants will learn the types of waste, lean and traditional manufacturing; the barriers to lean, implementation of lean and progress toward lean; the 5 elements of 5S, elimination of waste and waste identification; the typical steps to complete a current state drawing and typical results; the implementation of change and the wrong ways to address roadblocks; the difficulties with human error; the seven guidelines to Poka Yoke attainment and the Poka Yoke systems that govern the process; and the methods for using Poka Yoke, contact methods, counting method and motion-sequence method
        • Module 1 - What are the Lean Manufacturing Tools?

          Contents:
            • What Are the 5 Principles of Lean Manufacturing?
            • What is Lean Manufacturing PPT?
            • What are Lean Techniques in Manufacturing?
            • FMEA as Lean Tool
            • Ideas of Lean
            • Improving Service Quality
            • Value Stream Mapping a Popular Lean Process Tool
            • Value Stream Mapping
            • VSM Commonly Used Symbols
            • Can you Interpret this VSM?
            • Value Stream Mapping Method
            • Whose Perspective do We Capture in VSM?
            • Lean Process Improvement Techniques
            • Workplace 5S
            • 7 Process Wastes (TIMWOOD)
            • Floor Layout Analysis (Spaghetti Diagram)
            • Capacity and Queuing
            • Process Map & Processing Time Value Analysis
            • Updates on the Term Project Paper
            • Final Term Project's Charter
            • Video: Process Optimization
            • Module Quiz
          • Module 2 - Lean Manufacturing Overview

            Contents:
              • Lean Manufacturing
              • Definitions
              • What is Lean?
              • Video: Four Principles Lean Management - Get Lean in 90 Seconds
              • Thinking Lean
              • Benefits
              • Toyota Production System (TPS)
              • Types of Waste
              • Lean vs. Traditional Manufacturing
              • Barriers to Lean
              • Implementing Lean
              • Progress Toward Lean
              • Lean Is A Journey
              • 5S & Visual Control
              • 5S and Visual Control
              • 5 Elements of 5S
              • Why 5S?
              • Types of Waste
              • Elimination of Waste
              • Waste Identification
              • After 5S
              • Workplace Observation
              • Sort
              • Straighten
              • Shine
              • Standardize
              • Sustain
              • Visual Factory Implementation
              • Kaizen
              • What is Kaizen?
              • Identify the Customer
              • Types of Waste
              • Identify the Current State
              • Brainstorm and Analyze
              • Implementation Plan
              • Execute
              • Check and Sustain
              • Kaizen Blitz
              • Kaizen Blitz - Agenda
              • Roadblocks
              • Value Streams
              • Outline
              • What Are Value Streams?
              • Types of Value Streams
              • Identifying the Value Stream
              • Value Stream Mapping
              • The Current State
              • The Future State
              • Implementing Change
              • Roadblocks
              • Wrong Ways to Address Roadblocks
              • Module Quiz
            • Module 3 - Pull Manufacturing

              Contents:
                • Why Pull Manufacturing?
                • Push vs. Pull Scheduling
                • Inventory Hides Problems
                • Lowering Inventory Reveals Problems
                • What is Just-in-Time?
                • Objective of JIT
                • JIT Principles
                • Quality Enables JIT
                • How to Accomplish JIT Production
                • Kanban
                • Kanban Squares
                • Kanban Card
                • Video: Lean Manufacturing - Kanban
                • Quality at the Source
                • One Piece Flow
                • Continuous Flow
                • Pull Production
                • Pull System
                • Standardized Work
                • Work Balancing / TAKT Time
                • Production Smoothing/Leveling
                • Wrap-up - Pull Manufacturing
                • Mistake Proofing (Poka Yoke and Error Proofing)
                • What is Mistake Proofing?
                • Everyday Examples
                • Evidence of the Effectiveness
                • Mistake Proofing ROI
                • 1-10-100 Rule
                • The Difficulties With Human Error
                • Error Proofing & SPC
                • “Be More Careful” Not Effective
                • What Causes Defects?
                • Inspection Techniques
                • Poka Yoke
                • Module Quiz
              • Module 4 - Lean Manufacturing Overview

                Contents:
                  • Seven Guidelines to Poka Yoke Attainment
                  • Poka Yoke Systems Govern the Process
                  • Common Mistake proofing Devices
                  • Methods for Using Poka Yoke
                  • Contact Methods
                  • Counting Method
                  • Motion-Sequence Method
                  • Types of Sensing Devices
                  • 3 Rules of Poka Yoke
                  • Quick Changeover Single Minute Exchange of Dies
                  • Changeover Defined
                  • Changeover Time Defined
                  • Traditional Approach
                  • Another Way
                  • Benefits of Setup Reduction
                  • Classification of Setup Activities
                  • What is SMED?
                  • Single Minute Exchange of Dies
                  • Why SMED?
                  • SMED Methodology
                  • The SMED Process
                  • Preliminary Stage
                  • Stage 1
                  • Stage 2
                  • Stage 3
                  • Stage 4
                  • The SMED System - Results
                  • Six Sigma
                  • What is Six Sigma?
                  • Video: What Is Six Sigma
                  • Why Companies Need Six Sigma
                  • How Good is Good Enough?
                  • Six Sigma as a Metric
                  • 3 Sigma vs. 6 Sigma
                  • Six Sigma ROI
                  • Six Sigma as a Philosophy
                  • Six Sigma Tools
                  • Problem Solving Methodology
                  • Define Phase
                  • Measure Phase
                  • Evaluate/Analysis Phase
                  • Improvement Phase
                  • Design of Experiments (DOE)
                  • Control Phase
                  • What is Design for Six Sigma (DFSS)?
                  • DFSS Methodology & Tools
                  • Green Belts & Black Belts
                  • Module Quiz
                • Module 5 - Activity Based Costing and Lean Accounting

                  Contents:
                    • What is Cost Accounting?
                    • Traditional Cost Systems
                    • Overhead Costs
                    • Activity-Based Costing
                    • Unit Costs Under ABC
                    • Benefits of Activity-Based Costing
                    • Benefits of ABC
                    • Limitations of ABC
                    • When to Use ABC
                    • Activity-Based Management
                    • Lean Accounting
                    • Lean Accounting – The Lean Transition
                    • Lean Accounting – Management Accounting
                    • Lean Accounting – Business Management
                    • Lean Accounting – Operational Accounting
                    • Lean Accounting – Financial Accounting
                    • Video: ABC/ABM Understanding Manufacturing Costs
                    • Theory of Constraints
                    • Constraints
                    • Significance of Bottlenecks
                    • Theory of Constraints
                    • What is the Theory of Constraints?
                    • What is TOC?
                    • How does TOC Help Companies?
                    • Five Steps Of TOC
                    • Theory of Constraints
                    • Steps in the TOC Process
                    • Drum Buffer Rope
                    • Lean: How DBR Supports it Fundamentally, Don’t Build Until Needed
                    • Why Drum Buffer Rope?
                    • Issues with TOC
                    • Measurements
                    • Traditional vs JIT, TQM and TOC
                    • The “Cost World”
                    • The “Throughput World”
                    • Financial Issues
                    • Conclusion
                    • Module Quiz
                  • Module 6 - Human Factors

                    Contents:
                      • Ergonomics
                      • What is Ergonomics?
                      • What Makes an Effective Program?
                      • Causes & Contributing Factors
                      • Hazard Prevention & Control
                      • Ergonomic Modification Process
                      • Work Practice Controls
                      • Work at Working Safely
                      • Knowledge Management
                      • Why Knowledge Management?
                      • Barriers to Knowledge Management Success
                      • Summary
                      • Video: Knowledge Management
                      • Rewards & Recognition
                      • Safety & Health
                      • Cost of Accidents
                      • Legal Issues and Liability
                      • Accident Causes
                      • Establishing Accountability
                      • Defining Responsibilities
                      • Effective Teams
                      • Your Organization Can Benefit from Teams
                      • The Importance of Creating High Performance Teams
                      • The Five Stages of Team Development
                      • Conducting Effective Meetings
                      • Module Quiz
                    • Module 7 - An Introduction to Lean Six Sigma (6σ)

                      Contents:
                        • Six Sigma - As Easy to Understand As Parking Your Car
                        • Agenda
                        • History of Quality in Higher Education
                        • The World We Live In
                        • What is Six Sigma (6σ)?
                        • Six Sigma Concept
                        • What’s Wrong With 99% Quality?
                        • Why Use Sigma as a Metric?
                        • Limitations of Average-Based Metrics
                        • Where Did 6σ Come From?
                        • Isn’t 6σ Just For Manufacturing?
                        • Six Sigma (6σ) in Academia
                        • Six Sigma (6σ) Methodologies
                        • DMAIC Methodology
                        • Video: What is DMAIC-
                        • Six Sigma Toolbox
                        • Project Focus
                        • Different Views of the Organization
                        • So, What is Lean?
                        • Where Did Lean Come From?
                        • Core Ideas of Lean
                        • The Seven Speed Bumps of Lean
                        • The Antidote to Waste: The 5 S’s
                        • Synergy of Lean and Six Sigma
                        • The Birth of “Lean Six Sigma”
                        • Pareto Chart in Residence Halls
                        • Using Pareto and Trend Analysis
                        • Control Chart for Hot Water in Residence Hall
                        • Regression Analysis
                        • Reference Our Master Improvement Story
                        • DMAIC: Define the Project
                        • DMAIC: Measure the Current Situation
                        • DMAIC: Analyze to Identify Causes
                        • DMAIC: Improve
                        • DMAIC: Control
                        • To Recapitulate Six Sigma
                        • Module Quiz
                      • Module 8 - Lean Manufacturing

                        Contents:
                          • Definition
                          • Lean and Just-in-Time
                          • What is Waste?
                          • Seven Wastes
                          • Origins
                          • Underlying Principles to TPS
                          • Toyota Production System
                          • Timeline
                          • Key Lean Manufacturing Techniques
                          • 5S
                          • 5S Examples
                          • Benefits of 5S
                          • 5S Drawbacks
                          • Single Minute Exchange of Dies (SMED)
                          • SMED and Lean
                          • Video: SMED and the Eight Principles
                          • Simple CNC Example
                          • SMED Examples
                          • Benefits of SMED
                          • Kanban
                          • Kanban Example
                          • Benefits of Kanban
                          • Cellular Manufacturing
                          • Benefits of Cellular Manufacturing
                          • Lean Manufacturing Advantages and Disadvantages
                          • People
                          • How People Benefit from Lean
                          • How Customer’s Benefit from Lean
                          • House of Lean
                          • Economics
                          • Changes in Lean Since the Beginning
                          • Inventory Comparison
                          • Quality Control
                          • Lean Maintenance
                          • A Simultaneous Approach
                          • 6 Tools for Lean Maintenance
                          • Lean Philosophies Linked to Maintenance
                          • Other Impacts of Lean
                          • Background
                          • Problems
                          • Results
                          • Module Quiz
                        • Module 9 - Case Studies

                          Contents:
                            • Case Study 1:  55 Process Improvement Case Studies & Project Results [2021] 
                            • Case Study 2: Optimization of Oxime Formation Process
                            • Case Study 3: Minimizing Waste Using Lean Manufacturing: A Case in Cement Production
                            • Case Study 4: Process Optimization by using Lean Manufacturing Technique (Six Sigma) – A Case Study in Manufacturing Industry
                            • Case Study 5: Lean Principles and Optimizing Flow: Case Studies 
                            • Case Study 6: Bringing Together Lean and Simulation: a Comprehensive Review
                            • Case Study 7: Integrating Simulation-Based Optimization for Lean Logistics: A Case Study 
                            • Case Study 8: A Case Study of Lean, Sustainable Manufacturing 
                          • Post-Test

                            Kindly complete the post-test to assess your knowledge about the topic after the course.