Implementing a Lean System

The Strategy
The strategy for this training function involves the formation of Lean Teams. These teams identify an opportunity for improvement and apply the principles, concepts, and techniques presented in the proposed training. Measurements are established to measure the effectiveness of all initiatives resulting from the training.
The starting position of this process is Phase I, a plant-wide presentation of Lean Manufacturing. This provides a common knowledge base, answers questions and clearly defines the goals of a Lean Manufacturing Process.
Additional training is further defined and developed to address specific applications and processes within the company. A brief synopsis of Lean Manufacturing is attached to this document.

Required Training: Phase I

Lean Manufacturing Overview



Upon completion of this course, the participant will have an understanding of the concepts,
principles, tools, and implementation requirements of the Lean Manufacturing Function.
  • What is Lean?
  • Quick Change-over
  •  Error Proofing
  • Value Stream Mapping
  • Continuous Flow
  • Visual Management
  •  Workplace Organization (5S)
  •  Standard Work
  • Work Groups (Team Building)
  • Supply Base Management
  • Information Flow Management
  • Total Productive Maintenance (TPM)
  • Kaizen Based Manufacturing
  • Need for change
Topics of Discussion
  • PDCA Model – Plan-Do-Check-Act (Problem Solving)
  • Flowcharting to gauge current processes
  • Process mapping to eliminate process constraints
  • Identifying the seven wastes in your organization
  • Developing a 5S visual program
  • Implementing Kaizen events for continuous improvement
  • Standardizing of operations
  • Set up reduction
  • Process capability improvement
  • Cellular implementation
  • Implementing Kanban systems
  • Visual management throughout your organization
Required Training: Phase II
Additional Training and Workshop Facilitation
xx hours
The presentation strategy of each course is delivered to specific audiences and incorporates
specific (your company) examples that have been selected as candidates for improvement.
Mini courses are presented to defined audiences.

These courses address the following topics:

  • Quick Change-over or Single Minute Exchange of Dies (SMED)
  • Error Proofing
  • Continuous Flow
  • Visual Management
  • Workplace Organization (5S)
  • Standard Work
  • Work Groups (Team Building)
  • Supply Base Management
  • Information Flow Management
  • Total Productive Maintenance (TPM)
  • Kaizen Based Manufacturing (see attachment)
  • Need for change

The sequence of activity for the Lean initiative is:

  • In-Depth Area Training
  • Form Area Lean Team
  • Develop and Approve Team Charter
  • Develop Area Implementation Strategy
  • Implement 5S
  • Review and Maintain 5S Process
  • Develop Lean Audit System
  • Select a Process for Value-Stream Mapping
  • Select an opportunity within the process
  • Use the Problem Solving Process to create action items
  • Implement action items and review for effectiveness
  • Establish visual management tools
  • Implement Monthly Meeting protocol for the Lean Team
About Lean Manufacturing
Lean manufacturing principles represent a radical departure from traditional plant
techniques and their resulting systems. The Lean Manufacturing systems are highly
flexible and responsive to customer requirements.

The employee’s roles, skill-sets, process-requirements and rules have changed. Team
members must operate like an independent business with total responsibility for the
quality, manufacturing and delivery of the product to their customers. Team members
need to be empowered with current information, dedicated resources, and established
boundaries to accomplish their mission.

Lean Manufacturing is both a philosophy and a set of guiding principles that represent
the foundation of a continuously improving organization.

Lean Strategies are the application of quantitative methods and human resources to
improve the material and services supplied to an organization, all the processes within
an organization, and the degree to which the needs of the customer are met, now and in
the future.

Lean Manufacturing integrates fundamental management techniques, existing improvement efforts, and technical tools under a disciplined approach focused on Kaizen-Continuous Improvement. Lean manufacturing has turned motion reduction into a science and an art.

The Basic Elements of Lean Manufacturing
  • Elimination of Waste: Waste is defined as anything that consumes material or
    labor and that does not add value to the final end customer.
  • Equipment Reliability: Equipment that runs when production requires it to run
  • Process Capability: Processes that always make good parts.
  • Continuous Flow: Material flows one part at a time vs. mass production using big batches. Less inventory required throughout the production process, raw material, WIP, and finished goods, reduces defects
  • Lead Time Reduction: Speeds up order to delivery
  • Error Proofing: Ways to prevent the product from being built incorrectly
  • Stop the Line Quality System: The production line is stopped when bad quality is being produced.
  • Kanban System: Kanban is a pull material system. The material is pulled through the production process by customer demand. Kanban uses cards to move material along the value stream.
  • Standardize Work: Standardized Work is a system of organizing work steps and documenting them. The team leader prepares the Standard Work.
  • Visual Management: When a plant utilizes Visual Management fully, a new employee can understand how to do his job from the visual information in the plant
  • In Station Process Control: Each workstation has the information and equipment or the worker to inspect and produce good quality parts.
  • Level Production: Production is leveled to customer demand.
  • Takt Time: Production is paced to customer demand. Takt Time =Time available to produce a product divided by the number of parts that the customer wants to buy.
  • Quick Changeover: A system to change-over from one product to another quickly.