Lean Manufacturing (PowerPoint PPTX)

"Lean" is a management philosophy based on the Toyota Production System (TPS). With Lean manufacturing, you will be able to enhance value for your customers by streamlining process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources. The Lean approach shows you how to increase profits by reducing the cost of waste. And lean is a practice consisting of continuous experimentation to achieve perfect value with zero waste.

Based on the Lean philosophy, all activities in an organization can be grouped into two categories: value-added (VA) activities, and non-value-added (NVA) activities. It should be noted that VA and NVA activities (waste) are viewed from the customer perspective.

VA activities are those that bring higher value to products and services. Examples are answering customer queries, entering orders, ordering materials, laying foundation, creating codes, assembling parts, shipping of goods to customers, etc. Customers are willing to pay for these improvements which can change the form, fit or function of a product or service.

On the other hand, NVA activities are tasks that add cost or time but do not add value. Examples are filing, copying, recording, waiting, counting, checking, inspecting, testing, reviewing and obtaining approvals. These activities should be eliminated, simplified or reduced as much as possible.

By tackling waste from an end-to-end business process, not only can your company improve the value of its products and services, you can also achieve significant cost reduction, strengthen cash flow and emerge from the pandemic or downturn with a stronger and more competitive profile.

By teaching this Lean manufacturing PPT presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.

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NOTE: 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 & TOOLS
•  Muda, Mura & Muri
•  Gemba framework
•  4Ms
•  5S principles
•  Visual management
•  Plant layout
•  Cellular layout
•  Total Productive Maintenance
•  Standard work
•  Heijunka (Leveling)
•  Kaizen
•  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