Lean Manufacturing

Our Practical Energy training educates businesses and their employees on what they can do to minimize energy consumption. This course is not laden with heavy theory, but instead is filled with practical ideas a company can immediately implement to slash their utility bill and improve their bottom line. Practical Energy services and training provide low-cost solutions for saving energy typical paybacks of 20-to-1.

Kaizen events are the vehicle to implementing Lean tools and concepts. Kaizen events are well-scoped, focused improvement efforts that utilize a team-based approach to eliminating wastes.  The greatest benefit of a kaizen event is the nearly instantaneous recognition of improvement.  Aggressive goals are set early in the process and solutions are not simply put on paper but implemented by the team. Team members are empowered to offer and implement ideas, reinforcing the notion they are having an immediate impact.  Kaizen events are a proven way to implement Lean tools.

Value Stream Mapping is a planning tool to help companies focus on when and where they should apply Lean concepts to get the most impact.  The VSM process consists of identifying value streams/product groups in the organization, mapping a current state of material and information flow and assessing the inherent wastes and designing a future state of how the value stream is desired to perform.  The result is an implementation plan that clearly prioritizes when and where to focus improvements and how each improvement will help achieve the future state.

Pull/Kanban is based on the concept of building products based on actual consumption. The system uses visual signals when parts need to be replaced.  Attendees learn how to control shop floor inventory and production schedules by implementing pull systems. This workshop teaches how to design and implement a visually driven, employee controlled material replenishment system. Participants also learn how to implement repetitive and non-repetitive pull systems, set up point-of-use material storage, interface with planning systems and balance lot size with capacity.

Through the arrangement of people and equipment into efficient, process-based cells, cellular manufacturing creates a smooth flow that shortens the lead time for delivery while supporting low inventory production, space saving and continuous improvement.

This workshop teaches the fundamental principles of setup reduction. Setup is clearly defined. Both reasons for and barriers to reducing changeovers are presented.  The seminar follows the principles outlined by Shigeo Shingo on Single Minute Exchange of Dies (SMED). Participants learn the standard methodology in applying SMED to any type of setup or industry.  This workshop includes a live simulation where students get hands-on experience in setup reduction.

Lecture and hands-on simulations introduce standardized work, workplace organization, visual controls, set-up reduction, batch size reduction, point-of-use storage, quality at the source, workforce practices and pull systems. Participants assemble test circuit boards in a simulated manufacturing setting. Results of the first simulation round provide the setting for continuous improvement applying Lean enterprise principles to reduce the eight wastes.

• Definition of TPM
• Need for TPM
• Levels of maintenance
• TPM implementation roadmap
  • Plan
    • Training
    • Policies and goals
  • Apply
    • Autonomous maintenance
    • Pilot kaizen
    • OEE
    • 6 major losses
  • Deploy
    • Visuals
    • Operator PM
    • Maintenance PM
    • Spare parts
  • Integrate
    • CMMS
    • Predictive maintenance
    • Life cycle cost
  • Excel

This workshop is an excellent course for introducing participants to the basic principles of lean enterprise.  Lecture material provides an overview of the background of lean, the eight deadly wastes of manufacturing and the lean tools used to eliminate those wastes.  The course also offers participants the opportunity to participate in a simulated factory to see first hand the application of lean concepts and their benefits.

Learn how to transform a factory into a place where information concerning product quality, productivity, schedule and safety are visually accessible at any given moment.

Participants learn the 5 S methodology to implement specific, easy-to-access visual systems to enhance communications and productivity.