Lean Manufacturing

Course Title: Lean Manufacturing Training

Course Duration: 2 Days (8 hours/day)

Course Outline

Day 1: Fundamentals of Lean Manufacturing

1. Introduction to Lean Manufacturing
   • History and Evolution of Lean Principles
   • Core Concepts of Lean: Eliminating Waste, Creating Value
2. Understanding the 7 Wastes (Muda)
   • Overproduction, Waiting, Transport, Overprocessing, Inventory, Motion, Defects
3. Lean Tools and Techniques
   • 5S Methodology
   • Value Stream Mapping (VSM)
   • Kaizen and Continuous Improvement
4. Lean Culture and Mindset
   • Developing a Lean Culture
   • Leadership’s Role in Lean

Day 2: Lean Implementation and Advanced Tools

1. Lean Implementation Roadmap
   • Identifying and Mapping Processes
   • Gap Analysis and Waste Identification
   • Action Planning
2. Advanced Lean Tools
   • Just-in-Time (JIT)
   • Kanban Systems
   • Total Productive Maintenance (TPM)
3. Measuring Lean Success
   • Key Performance Indicators (KPIs)
   • Metrics for Lean Performance
4. Case Studies and Simulations
   • Real-Life Examples of Lean Success
   • Hands-On Simulations
5. Lean Sustenance
   • Strategies for Sustaining Lean Practices
   • Overcoming Resistance to Change

Course Objectives

• Understand the principles and philosophy of Lean Manufacturing.
• Learn tools and techniques for identifying and eliminating waste.
• Develop skills to create value and improve processes.
• Gain practical experience in applying Lean tools and techniques.
• Create an action plan for implementing Lean in a work environment.

Learning Outcomes

By the end of the course, participants will:

1. Recognize the seven types of waste and understand their impact on efficiency.
2. Apply Lean tools such as 5S, VSM, and Kaizen in practical scenarios.
3. Develop skills to identify bottlenecks and inefficiencies in processes.
4. Understand how to implement a Just-in-Time system and Kanban.
5. Formulate actionable strategies for sustaining Lean practices.

Methodology

1. Interactive Lectures
   • Theory supported with real-world examples.
2. Workshops and Group Activities
   • Hands-on exercises in process mapping and waste identification.
3. Case Studies and Examples
   • Analysis of successful Lean implementations in various industries.
4. Simulations
   • Practical application of Lean principles through real-life scenarios.
5. Assessments and Feedback
   • Quizzes, group presentations, and action plan development with instructor feedback.
6. Implementation Roadmap
   • Guidance on creating a Lean strategy for participants' organizations.