Lean Manufacturing (PowerPoint PPTX)

In this Lean Manufacturing presentation, we explore the Lean philosophy, which is rooted in the Toyota Production System (TPS). Lean aims to enhance customer value by optimizing processes and eliminating waste, ultimately increasing productivity and value with fewer resources.

A key aspect of Lean is distinguishing between two types of activities: value-added (VA) and non-value-added (NVA) activities, assessed from the customer's perspective.

VA activities deliver value to products and services, such as answering customer queries or assembling parts, enhancing form, fit, or function, which customers are willing to pay for.

Conversely, NVA activities, like filing or waiting, add cost or time but do not contribute value and should be minimized or eliminated.

By addressing waste across the entire business process, organizations not only enhance the value of their offerings but also reduce costs, improve cash flow, and increase competitiveness, particularly in challenging times like a pandemic or downturn.

This Lean Manufacturing presentation equips managers and employees with a better understanding of Lean principles, waste elimination, and encourages active involvement in Lean implementation, promoting a culture of continuous improvement.

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This training package includes:
1. Lean Manufacturing PPT training presentation (PowerPoint format, 16:9 widescreen)
2. Lean poster (PDF format, in color and monochrome, printable in A3 size)
3. Eight Wastes of Lean poster (PDF format, in color and monochrome, printable in A3 size)
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LEARNING OBJECTIVES

1. Acquire knowledge on the key concepts and principles of Lean
2. Describe the Lean methods and tools for waste elimination and value creation
3. Describe the key roles in Lean deployment
4. Define the success factors for sustaining a Lean culture

CONTENTS

1. Introduction to Lean Manufacturing
•  The case for Lean Manufacturing
•  History of the Toyota Production System
•  Toyota's management philosophy
•  What is Lean?
•  Five principles of Lean
•  What Lean is not
•  Lean adoption in various environments
•  Impact of Lean principles in industry
•  Lean applications in manufacturing, process and service industries
•  Traditional thinking versus Lean thinking
•  Traditional culture vs. Lean culture
•  Lean management framework
•  Benefits of Lean manufacturing

2. Key Concepts of Lean
•  Methods to increase productivity
•  What is waste?
•  Work versus waste
•  Value defined
•  Cost reduction principle
•  Eight types of manufacturing waste
•  Examples of value-added and non-value added activities
•  Lean thinking philosophy
•  Lean emphasis

3. Lean Methods and Tools
•  Muda, Mura & Muri
•  Gemba framework
•  4Ms
•  5S principles
•  Visual management
•  Plant layout
•  Cellular layout
•  Total Productive Maintenance
•  Standard work
•  Heijunka (Leveling)
•  Kaizen
•  Value stream mapping
•  Pull systems / Kanban
•  Continuous flow
•  Takt time
•  Quick changeover / Set-up reduction
•  Flexible workforce
•  Quality at the source
•  Poka-yoke (mistake-proofing)
•  Andon
•  Problem solving
•  Small-group activities
•  Suggestion system
•  Hoshin Kanri

4. Lean Roles
•  Lean steering committee
•  Lean deployment leader
•  Lean champions
•  Lean process owner
•  Lean coach
•  Lean team leader
•  Lean team members

5. Sustaining a Lean Culture
•  Challenges in Lean manufacturing
•  Understanding responses to change
•  Sustaining a Lean culture
•  Lessons from other adopters