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Lean Manufacturing/Toyota Production System
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| TPS Overview |
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The Toyota Production System! So much has been written about it, yet there is still so much misunderstanding!
Comments from management abound such as “I want this implemented within 30 days! to “We can’t afford the capital outlay for lean manufacturing!”
This presentation will separate the facts from the myths and take the mystery out of what “going lean” is all about.
Topics such as:
- The cost/selling price/profit equation
- Traditional vs. Lean Manufacturing
- Elements of the Toyota Production System
- 5S
- Problem Solving
- Kaizen
- Kanban
- Error Proofing
- Quick Changeover
- Standardized Work
- Total Productive Maintenance
- Visual Management
- The 7 Wastes
- Value Added vs. Non Value Added activities
- How to prioritize cost reduction opportunities
- Shop Floor Activities
- Methods Study
- Work balancing/line element (1 piece flow)
- Reorganization of work steps and flow
- Implementation of new work steps
Attendees will leave with a good foundation of TPS and the requirements for a successful implementation in reducing waste, increasing output, raising quality levels, reducing costs, and improving customer satisfaction. |
| 5S/Visual Management |
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Ask any seasoned manager and they will tell you the first thing that affects every aspect of their operation is poor housekeeping. Ask again and they will tell you the number one problem in getting things accomplished is ineffective communication.
Understanding 5S and Visual Management are a must to begin the journey to a lean organization focused on customer service. Toyota, as the world leader in lean manufacturing, developed these concepts and practices in order to achieve their world class success. Learn why Toyota believes these practices are two of the key elements of the Toyota Production System.
This course will cover techniques which allow you to effectively communicate all aspects of your business to your management, employees, and anyone who walks in the door and make your facility “tour ready” at all times. No more overtime and last minutes clean ups when your visitors call. Learn how employing the 5S’s can improve productivity, reduce maintenance costs, and improve customer response time.
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| Lean Simulation |
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This training is for those really interested in taking the next step in, not just learning, but implementing a lean environment in their manufacturing facility. During the course of 3-4 hours, through a combination of instruction, class room participation, and hands-on activities, the participants will demonstrate to themselves how much more efficient (and easier for those performing the work) lean is over traditional manufacturing. The class will learn theory and then put into practice a mock manufacturing setting in several different simulated production environments.
First, the traditional arrangement employs fixed lots of various sizes in isolated, specified work centers. Material is moved from department to department by a material handler. All work is routed through an inspector to “insure quality”. Measurements of productivity, quality, elapsed time and inventory investment are made to establish a base line.
In subsequent iterations, work cells are configured to integrate manufacturing, subassembly, final assembly, self-inspection, and packaging of the product to exact customer demand. The work is balanced in non-traditional combinations. Material is transferred (“pulled”), from person to person, one-at-a time, only as needed.
Measurements at the end of each phase show remarkable improvements in productivity, quality, elapsed time, and inventory investment. Participants will truly understand how beneficial this new methodology can be to them. The skills learned can be easily transferred upon their return to the shop floor.
This training can be conducted as a stand alone class, as described above, or as part of a 3 ½ day kaizen (continuous improvement) event on your own shop floor (see the training description for Kaizen Event for further details). |
| Variance Pricing |
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| Remember the days when all you had to do was get three bids, ensure that the supplier was “qualified”, and then select the lowest bidder? This assumed that following this practice would provide the lowest cost. The world has changed. As customer demands for cost reductions expanded beyond the automotive industry, the world of purchasing has changed as well. Add to this the higher expectations from “corporate” for lower prices and more value from the supply base, and our past procurement systems become outdated very quickly.
Enter Variance Pricing. Simply put, Variance Pricing begins with the buyer requiring very detailed and precise costing information from the supplier. The buyer must be specialized in each commodity on their purchasing deck or, at the very least, have a manufacturing background so as to determine the supplier’s quotation as either fantasy or reality.
Come learn how to set up a Variance Pricing program in your company, its’ role in achieving the lowest possible cost for purchased goods and services, how it enhances reductions in the supply base, and how it leads the way for year over year purchase price reductions.
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| Kaizen Event |
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| A Kaizen Event is a tool to discover and remove waste from a process (E.g. manufacturing) through education of the work force, observation, and implementation of elements of the Toyota Production System (TPS).
This seminar takes the lessons learned within the classroom and puts them into practice on the shop floor by reducing waste, increasing output, raising quality levels, reducing costs, and improving customer satisfaction. This training is for those really interested in taking the next step in not just learning, but implementing a lean environment in their manufacturing facility. During the course of 3-4 days, through a combination of instruction, class room participation, and hands-on activities, the participants will demonstrate to themselves how much more efficient (and easier for those performing the work) lean is over traditional manufacturing. The class will learn theory and then put into practice the improvements they have discovered with their new found tools.
Course participants are plant floor team members, team leaders, engineers, and other support personnel. The approach of developing lean skills deep into the organizational structure allows for future improvements long after the class is over.
Each event shall include:
- Development of event goals and objectives
- An overview of the Toyota Production System (TPS) including:
- Defining continuous improvement (including the cost/profit/price relationship).
- Traditional versus non-traditional manufacturing methods.
- Hands on exercises to demonstrate how reduction in the 7 Wastes will lead to cost improvement.
- J-I-T Simulations (Parts 1, 2, and 3).
- Standardized Work and how it relates to problem solving and finding hidden costs.
- Value Added vs. Non Value Added activities.
- How to prioritize cost reduction opportunities.
- Ship Floor Activities
- Methods Study.
- Identification of waste within the process.
- Work balancing/line element (1 piece flow).
- Reorganization of work steps and flow.
- Implementation of new work steps.
- The development of a cost reduction implementation time line.
The training will conclude with the class presenting to management the results and benefits they have achieved.
Dramatic improvements can be expected during this event! |
| Lean Manufacturing Assessment |
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The road to implementation of the Toyota Production System is a journey, not a destination. One method to achieving success is by determining a current baseline and then conducting periodic measurements to record progress.
For organizations new to TPS, participation in the TPS Overview training is a prerequisite. Upon completion, a facilitator will meet with the management team and review the elements of the assessment process and answer any questions the management team may have.
Assessment Areas include:
- Culture and Awareness
- 5S
- Visual Management
- Standardized Work
- Kaizen
- Error Proofing (Poka Yoke)
- Quick Changeover
- Total Productive Maintenance
- Inventory Control (including Logistics and Kanban)
- Problem Solving
- Training Programs
- Safety Programs
The management team will then conduct their own assessment and prepare the assessment form, rating the organization in each area. The facilitator team will then conduct an independent assessment and meet with the management team to compare each group’s findings. Discussion follows until a consensus is reached as to the standing of the organization in each area. A jointly developed action plan is then generated, with the establishment of goals and deadlines for improvements.
The process is continued, with or without the aid of a facilitator, as long as the organization continues to exist.
Continuous improvement is just that…continuous.
As with any improvement activity, a clear understanding of the criteria and goals, accompanied by a detailed action plan and top-to-bottom commitment, is essential to success.
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| Problem Solving |
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Americans are so impatient! Life in the modern workplace is fast paced. “Who has time for problem solving? We need answers now!” But is the way you handle problems really solving your problems, or does all of the rush and flurry of activity make it difficult, if not impossible to tell? One question you should ask yourself is “do any of our problems keep reoccurring? “ If your answer is yes, then this training is a must for your organization.
This is a hands-on class. Each participant should bring an actual workplace problem to the class. Learn how to work through the most difficult task of solving a problem, which is identifying what the problem is in the first place. Students will further learn why brainstorming and team consensus are such valuable tools and how employing a “fresh eyes” approach will uncover additional potential causes of the problem. Discover how to select the prime contributors of not just what caused the problem, but why did the problem reach the customer. Or worse yet, why is the customer the one to tell us we had a problem in the first place?
Lastly, you will learn how to measure your success, obtain ownership, set deadlines, and follow through to ensure your countermeasures are truly effective, not just over the next few days, but for good!
Class includes all course material. |
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