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| TRAINING |
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VALUE STREAM MAPPING SHOW || HIDE
• VSM workshop is Current State Map, Future State Value Stream Map and Value Stream Improvement Plan of selected value streams. Value stream maps are the blueprints for lean transformation.
• Value Stream Mapping is a critical initial step in lean implementation because it shows you where you could apply lean techniques to improve process capability and operational excellence to accomplish highest value. Mapping helps managers to avoid the common mistake of cherry-picking individual lean techniques, which creates isolated islands of improvement and limited benefits. COURSE OUTLINE: • Introduction • Value Stream Mapping • Selection of a Value Stream • ACME Stamping case study • Current State Mapping • Exercise • Identification of constraints • Creating Lean Flow • Design a future state Map • Identify lean tools for improvement • Develop Value Stream Improvement plan • Concluding session A3 THINKING: PROBLEM SOLVING TOYOTA WAY SHOW || HIDE
• Problem solving has been called the “DNA of the Toyota Production System.”
• A3 thinking is a rigorous problem solving process, which is an experimental test of any proposed changes for improvement. Viewing problem solving as primarily a cerebral activity it requires a logical thinking and scientific approach to detect the root cause, develop and implement right countermeasures. • Problem solving has been called the “DNA of the Toyota Production System.” COURSE OUTLINE: • Elements of A3 Thinking • How to select problems • Practical Problem Solving • Applications of A3 in different situations • Problem Solving Tools • A3 thinking & Six Sigma BUSINESS EXCELLENCE THROUGH LEAN MANUFACTURING SHOW || HIDE
A lean mind set is all about removing the wastes from manufacturing process, continuous improvement and Just in time (Procurement, Manufacturing). Every mind in lean environment is trained to indentify wastes in manufacturing process, finding the root cause.
COURSE OUTLINE: • Lean House with different pillars • Concept of Lean Manufacturing and One-Piece Flow • Definitions of Value & Waste • Kaizen – Continuous improvement • Tools and techniques to achieve Business Excellence through Lean • Detail on 5S, TPM, Quick Change over, VSM, Kanban, Visual Management • Poka Yoke – How to use • Measure Productivity, cost, Delivery and Morale • Lean Manufacturing with Toyota Production System • Learn how to create more value for customers by eliminating activities that are considered waste. Any activity or process that consumes resources, adds cost or time without creating value becomes the target for elimination. • Films and Photographs with case study to make it more practical KANBAN: REDUCING INVENTORY AT EACH STEP SHOW || HIDE
Kanban is a visual scheduling system that enables the process owner to easily view production requirements of individual parts and machines. Production personnel from the following process collect parts from the previous process leaving a Kanban card signifying the delivery of a given quantity of a specific part. When all the parts have been used, the same Kanban card is sent back, at which point it becomes an order for more
BENEFITS OF KANBAN SYSTEM: • Increased Inventory Turns • Lower Inventory Dollars • Improved Orderliness on the factory floor • Reduce wasted time looking for material • Real time scheduling • Reduce wasted floor space • Supplier control • No over production COURSE OUTLINE: • Understanding Kanban • How to operate Kanban on Shop • Kanban Card • Push & Pull systems • Synchronizing Kanban with Production • Systems used in Kanban -- Mitsuzumashi • Kanban Case Study presentation SMED – (SINGLE MINUTE EXCHANGE OF DIES) SHOW || HIDE
Single Minute Exchange of Dies (SMED) is the approach to reduce output and quality losses due to changeovers.
BENEFITS: • Increased customer service levels and profits Via Waste Elimination resulting in: • Reduced Lead Times-Faster Delivery • Zero Inventories-Reduced Working Capital • Improved Quality • Improved Safetybr/> COURSE OUTLINE: • Importance of SMED in Shop & Office • What is SMED • Traditional Set Up • Why SMED • SMED Advantages • MUDA (Waste ) – How to find define • Ground Rules of SMED • Andon Lamp Concept • SMED -- 10 Points of Implementation • SMED Charts • SMED Audit • Case studies SMED to Understand the Implementation • Films on SMED POKA YOKE – (MISTAKE PROOFING) SHOW || HIDE
Poka-Yoke (or Mistake Proofing) is one of the most effective waste elimination tools used to establish Lean Manufacturing in any organization. It is a way to produce the products that have zero defects by catching and fixing human mistakes and machine errors before they can cause defects. Poka Yoke is based on the Zero Quality Control (ZQC), which means a quality control system that ensures zero defects.
COURSE OUTLINE: 1) Importance of Poka yoke • How Poka yoke is Part of Kaizen activity • Global Competitiveness • Introduction to Zero Quality Control (ZQC) • Pokayoke Approach 2) Pokayoke Levels • Selection of Pokayoke Projects • Safety ignored examples • Pokayoke Reporting 3) Pokayoke 10 steps of Implementation • Human Tendency & Pokayoke • Examples of Pokayoke • How to build Pokayoke Culture TOTAL PRODUCTIVE MAINTENANCE (TPM) – (Zero defects, Zero breakdown, Zero accidents) SHOW || HIDE
Motives of TPM
• Adoption of life cycle approach for improving the overall performance of production equipment. • Improving productivity by highly motivated workers which is achieved by job enlargement. • The use of voluntary small group activities for identifying the cause of failure, possible plant and equipment modifications. TPM Objectives • Achieve Zero Defects, Zero Breakdown and Zero accidents in all functional areas of the organization. • Form different teams to reduce defects and Self Maintenance. • The use of voluntary small group activities for identifying the cause of failure, possible plant and equipment modifications. DIRECT BENEFITS OF TPM • Increase productivity and OPE (Overall Plant Efficiency) by 1.5 or 2 times. • Reduce the manufacturing cost by 30%. • Satisfy the customers’ needs by 100 % (Delivering the right quantity at the right time, in the required quality.) • Reduce accidents. INDIRECT BENEFITS OF TPM • Higher confidence level among the employees. • Keep the work place clean, neat and attractive. • Favorable change in the attitude of the operators. • Achieve goals by working as team. • The workers get a feeling of owning the machine. PROBLEM SOLVING TECHNIQUE SHOW || HIDE
COURSE OUTLINE:
• Introduction of Participants and Faculty • Overview of continuous improvement, and problem solving process – discussion of PDCA, CACI, SIPOC, Pareto tools • Identifying and defining the problem - Pareto, Trend chart, gap analysis, how to define a problem, teaming. • Determine and rank probable causes and prioritize - Critical observation, Brainstorming, Multivoting, Force Field Analysis, C&E diagram, C&E Matrix, 5-Whys, FMEA, Process Mapping. • Take Short Term action to protect customer - 100% inspection, import etc • Collect data, design test of causes - Data collection, Control chart, concentration diagram, check sheet, histogram, capability index, trend chart, DOE • Conduct test, analyze data, find root cause - Multivari charts, box plots, scatter plots, Matrix plots. • Plan and implement permanent solution - Poka Yoke, Piloting, comparison before and after. • Measure evaluate and recognize team OEE - (OVERALL EQUIPMENT EFFECTIVENESS) SHOW || HIDE
OEE is a "best practices" way to monitor and improve the efficiency of your manufacturing processes (i.e. machines, manufacturing cells, assembly lines).
BENEFITS: • Reduced manufacturing cost – Driving variable costs down through waste reduction. • Take full advantage of capital – driving overhead costs down by utilization improvement. • Reduction of working capital – Driving inventories down as process improve. FINANCIAL ASPECTS OD PURCHASE MANAGEMENT SHOW || HIDE
OBJECTIVES:
• Understanding of the procurement challenges of 21st century and also strategic aspects of procurement function. • Threadbare understanding of the various costs associated with the purchase department. • Understanding of the mathematical tools to be used in deciding the why and how much stocks to hold. • Analytical competence in deciding which vendor to choose. COURSE OUTLINE: • Shift in the role of Purchase department from Material Management to Supply Chain Management (SCM). • Traditional v New Age Procurement. • Elements of Strategic Procurement. • Inventory Costs and their break up. • How purchase function holds key to the finances of the company. • Various costs associated with Purchase function. • How to calculate Inventory Carrying Charges and Ordering Cost. • Concept of the Total Cost of Ownership (TCO) • How to calculate Inventory Carrying Charges and Ordering Cost. • Concept of the Total Cost of Ownership (TCO). • Understanding concept of Economic Order Quantity (EOQ). • How to implement ABC Analysis • How to calculate Total Material Cost(TMC) • Benefits of TMC for negotiations skills. • How to determine safety stock, minimum stock and maximum stock. • Scientific method of Vendor Assessment. • How to measure performance of Purchase Department. INNOVATION SHOW || HIDE
This one-day program takes you through a ‘Deep Dive’ on Innovation Practices of leaders and challengers, ranging from Apple to Google to 3M, BMW, Tata Motors and the likes; and help adopt these to your firm’s context. Further, Innovation being part Science and part Art, the program shares Tools & Techniques of systematically and systemically nurturing a Culture of Innovation within your organization. You would hone Creative and Problem Solving Skills at a personal level as well as further your organization on the Innovation Mission.
OBJECTIVES: • Understanding of the procurement challenges of 21st century and also strategic aspects of procurement function. • Threadbare understanding of the various costs associated with the purchase department. • Understanding of the mathematical tools to be used in deciding the why and how much stocks to hold. • Analytical competence in deciding which vendor to choose. OUTLINE OF COVERAGE • Talking in numbers • 20 Amenable Practices from Innovation Leaders. • 15 Tools & Techniques for Creative Problem Solving & Opportunity Creation • 2 Jam Sessions. SIX SIGMA SHOW || HIDE
COURSE OUTLINE:
• Introduction • What is Quality? • Importance of Quality • Variety and variations • Quality and Productivity / Lower costs / Best insurance against survival • Taguchi loss function • Special and common causes of variation • Six Sigma basics • Important Quality / Variations parameters • Average/Sigma/Cp/Cpk • Exercise in sigma calculations • Examples of relation between Sigma and Quality • Stages in quality journey • Process way - Importance of Process Improvement • Projects - Discussion on Opportunities and Projected benefits WHY DOE / 7 TOOLS OF DOE (DESIGN OF EXPERIMENTS: 1 Introduction 2 What is Quality? 3 Importance of Quality 4 Variety and variations 5 Quality and Productivity / Lower costs / Best insurance against survival OUTLINE OF COVERAGE • Multivari • Component Search. • Paired Comparison • Variables Search • Full Factorials • B Vs C • Scatter Plots |