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Lean manufacturing is based on observations of the Toyota Production System (TPS), a philosophy and set of methods for dramatically reducing time from customer order to delivery of a higher-quality product, with less cost, space, and inventory. This program will teach you how to provide your customers with what they want, when they want it.

Lean methods can help to streamline processes, reduce waste and improve efficiency everywhere in your organization, from the front office to the factory floor, to the emergency room.

By participating in the program participants will:

       Understand the history, philosophy and core methodologies of lean manufacturing.

       Learn to value stream map the current state of a product flow.

       Become able to develop a future state map of lean systems.

       Learn to create continuous flow through manufacturing cells.

       Develop the leadership techniques necessary to actively drive change and

 lean initiatives.

       USD1,350.000  - Fee includes instructional materials, breakfast, lunch and tea-breaks each day.

       Fee is payable in advance.  Upon receipt of payment, you will receive an email confirmation of your participation.

       This program will benefit any manufacturing, production, purchasing and supply chain professional.  

       Simulations are used to demonstrate hands-on lean concepts. The simulation moves from traditional push manufacturing to pull systems while key concepts such as 5S and one-piece flow are implemented. 

       Case studies from real companies are used to demonstrate tools and concepts.

       Lectures

       Simulations                                                                       

       Group discussions

       Group presentations

       All participants are requested to bring along a calculator.

 DAY ONE

1.       Mass Manufacturing to Lean Manufacturing Systems

       Grouping of machines layout towards cell layout

       1^st Simulation (Not Lean)

       Participants will take part in some assembly operations performed in a traditional way

       End of simulation calculate the group's performance

       Lead time, quality, productivity and inventory

2.       The Lean Principles

       Value

       The Value Stream

       Flow system

       Pull and the Kanban system

       Perfection

3.       Manufacturing Value Calculation

       Choose one of your products; calculate percentage of value added activities to your lead-time.

       This calculation is like a blood test to your process that reveals the whole world of improvements needed in your organization.  It is a way forward to Lean transformation.

4.       The 7 wastes.

       Identification and elimination of Muda, Mura and Muri.

5.       Kaizen Activities. 

DAY TWO

1.       2^nd Simulation – The cell manufacturing

       Reduction of manpower

       Elimination of departmentalization or grouping of machines

       Introduction of cell concept

       End of simulation calculate the group's performance

       Lead time, quality, productivity and inventory

       Cell manufacturing – cell layout. 

2.       Lean Tools

       The flow system

       The pull system

       The Drumbeat calculation (Takt time).

       Value Stream Mapping

       Quick Changeover (SMED)

       Poka Yoke 

3.       3^rd Simulation – Introducing the Pull System

       Practice Kanban

       Reduction of lot size and Heijunka

       End of simulation calculate the group's performance

       Lead time, quality, productivity and inventory.

4.       The Jidoka concept and quality improvement

       Poka Yoke 

5.       Elimination of non-value add activities and balance the line.

       Takt time calculation.

       Manpower calculations

       Gemba Genbutsu

       A world class case study will be introduced.

       Visual control.

6.       4^th Simulation (Lean) - A Group Project

       The group to design their own assembly line using formulae learnt.

       The group to eliminate all non-value add activities in their process and set up a lean line.

       Practice standard work.

       Line balancing.

       End of simulation calculate the group's performance

       Lead time, quality, productivity and inventory.

       Participants to compare the results of 1^st, 2^nd, 3^rd & 4^th simulation

       To make an evaluation of what is value add and non-value add in your organization. 

DAY THREE – LEAN IMPLEMENTATION

1.       Objectives

2.       The 2 principles of work

3.       Vision of TPS

4.       A Lean enterprise system

5.       Implement basic competency training

6.       Most important tools supporting Lean

7.       Achieving Lean leadership

       Total company involvement

8.       Lean leadership

9.       Lean implementation team members

10.    The Lean Roadmap

11.    Final thoughts

Our programs can be customized to meet your corporate needs and presented at a location of your choice.

Discuss your requirements with our Lean Sensei, Dr Andrew Jebamani at +6012-481 4755 or drop us a note to our email - mymc1@streamyx.com

 Dr Andrew Jebamani - B.Sc. (Industrial Engineering), MBA, MCIM (UK), PhD, LBC – Sensei

 Dr Andrew has an impressive record in the field of Operation Management for over 27 years. He is a senior member of the Society of Manufacturing Engineering, USA and has served the Multinational Companies in the capacity of Industrial Engineering Manager and Manufacturing Manager.   He was also instrumental in the implementation of many Get-Well programs.

 Dr Andrew is a trainer and consultant since 1995 and was awarded the Shingo Prize for Operational Excellence, USA (2007) and Lean Bronze Certification, USA (2008).  In 2011, Dr Andrew was awarded the Lean Manufacturing certification from the University of Michigan, USA. He brings with him a multi-disciplinary approach to the subject of Lean Manufacturing.  Starting from his "hands-on" production experience, he expertly weaves in the new knowledge-driven economy production paradigms to enable participants to appreciate why these techniques are so important in helping companies to compete in the global economy.  

He is a much sought after speaker and have presented several public and in-house training programs both locally and internationally.  Notable he has spoken to many companies in India covering major industrial areas. He was also invited to present similar seminars in China, Thailand, and Vietnam.  In November 2003, he was selected by the magazine "The Machinist" as the personality-of-the-month for Lean Manufacturing.

Dr Andrew is a highly capable trainer with a passion to assist companies acquire new management and production techniques to compete globally.  He is a leading consultant to the industry specializing in improving productivity with the holistic application of Lean, TQM, Management and Industrial Engineering Techniques.