Course Objective:
The main objective of this course is to answer many of the questions about Lean manufacturing concepts, "What concrete steps do I take on my next lean journey?" Lean manufacturing is a whole-systems approach that creates a culture in which everyone in the organization continuously improves processes and production. It is a system focused on and driven by customers, both internal and external. The workshop is offered to help you better understand some of the more common process-related tenets of lean manufacturing and the strategies necessary to support them.

Course Description

This course aims to guide the target audience towards better understanding of the Toyota Production System (TPS) which is behind the philosophy of Lean Manufacturing.  It will cover Lean principles and applications leading to better utilization of space, labor and machinery, in turn resulting in cost reduction and shortened lead time.  It also touches on some of the more common process-related tenets of Lean Manufacturing and the strategies necessary to support them such as standardization, problem-solving techniques and PDCA (plan, do, check, act).  The subject comprises of six modules as follows:

1.  Current State of the Garment Industry:  This module covers the analysis of low productivity and its root cause, identification of waste and failure in improvement.  It also addresses how factories must adapt their manufacturing systems in order to cope with marketplace changes with buyers’ demanding Just-in-Time production.
2.  Toyota Production Methodology:  This module covers the reasons behind the inception of TPS, its foundation and concepts such as the Four Rules of Toyota.  The trainer focuses on explaining the Three Pillars which led to the development of TPS.
3.  Waste Identification:  This module covers the methodology and tools used to identify waste in both in-process flow and everyday work practices.  Participants will learn how to map a product's production path (materials and information) from "door to door" and to assess work practices and processes to recognize waste.  Identifying the causes of waste serves as the foundation for Lean Improvement in reducing costs as well as process and overall lead-time to market.  There are two parts to this module: the first one identifies the factory’s current state and second draws and sets its future state.
4.  Continuous Flow:  This module covers the initial steps to achieving continuous flow by adapting to a team-based concept known as manufacturing cells.  It also covers one-piece flow vs. small lots; types of cells and in-cell flow; comparison between one-piece flow in sitting vs. standing; and methods of arranging operations, people and equipment within the cell.

5.  Supporting Strategies & Concepts: This module covers all basic Lean tools for the shop floor used to prevent waste and stabilize improvements.  Basic Lean concepts and principles are described and put into a practical context whereby participants will understand how they can be applied within the manufacturing environment.  Principles include: Kaizen, total productive maintenance workplace organization, visual management, standardized work, PDCA, problem-solving techniques, quality at the source, one-point flow, Takt and cycle time, etc. 
6.  Lean Roadmap:  This module covers the steps to undertake for Lean Transformation. It will also guide senior management and relevant staff in understanding their role and responsibility to then define where and how to start their Lean journey. 

The course will be an amalgamation of lectures, activities, discussions and self reflections

Who Should Attend

Industrial Engineers and technicians, work studies, factory managers or any other related to manufacturing improvement.