Lean Manufacturing

Course Description
The subject is aimed to guide the target audience for better understanding of the Toyota production methodology that leads to maximization of space, labor and machineries utilization resulting in cost reduction and shorten lead time in addition to some of the more common process-related tenets of lean manufacturing and the strategies necessary to support them. At the end, participants will understand why lean manufacturing is the ultimate solution. The subject comprises of 7 modules as follows:- Current State of the garment industry – This module covers the analysis of the low productivity and its root causes, failure in improvement including the reasons and also what factories must possess and adapt within the system due to the changes of the markets requirements and criteria. Toyota Production Methodology – this module covers the foundation and assets of Toyota, the methodology used to establish and design the cost of any given product at the initial development, the types of waste and the 4 practiced rules of Toyota in aligning the entire organization to common objectives and common skills and language. Waste Identification – this module covers the methodology and tools for identifying waste. The participants will learn on how to map a product's production path (materials and information) from "door to door" and how to assess the work practices and processes to recognize waste and identify its causes which can serve as the foundation for Lean improvement strategies in reducing costs, shorten process and lead time to market. Cellular Manufacturing – this module covers the initial steps for preparing and planning for cellular manufacturing and how to formulate the team cells and cell design which includes simulation of operations breakdown for better balancing and ration machine-man including the team development programme. The session will also cover the comparison between one piece flow in sitting vis-à-vis standing and the methods of arranging people and equipment into cells. Supporting Strategies & Concepts – this module covers all the basic lean tools to prevent waste. The participants will learn about the principles of Kaizen, workplace organizations, reduction in processes set up, quality at the source, establishing balanced flow, standardizing of work practices, connecting processes to one point flow, stabilizing of the manufacturing flow and connecting the workers to the corporate objective “Cost and Lead time” using the Takt time as the trigger for both achievements. Point-Of-Use Systems – This module covers the importance of the data, tools and equipment to be centralized at the area where the work is performing avoiding reliance on other. Lean Roadmap – This module covers the 8 steps plan to be undertaken toward the shifting achievement to lean. Also it will guide the top management and staffs in understanding the role of the lean forum and the changes in engineering daily functions and the importance of their role within the lean culture.
Who should attend:
Managing Directors, Senior managers, factory / production / Quality and Human Resources, marketing and purchasing managers, industrial engineering / work study team, planners, and manufacturing departments In Charge.
Objective:
To briefly understand the improvement-complexity within the conventional line systems. To identify the reasons and the root causes of low productivity To understand how Toyota production methodology can reduce cost tremendously and to shorten lead time. To be able to map existing production lines, identify waste and define areas for improvement. To design an efficient and economical production concept such as team cell that eliminates all waste related to conventional production lines. To understand the important needs and the application of the lean tools and how to apply them. To be able to design a roadmap for implementing Toyota Production Methodology.
Subject Content:

Subject Topics	Sub Topics	Specific Learning Outcomes
Current State of the Garment Industry	- Characteristics of the current industry - Factory Drivers - Improvement failure - Costing methodology and plant feasibility - Costing, lead time and quality drivers - Workforce structure - Center of Gravity of the business - Changing in Market criteria - Summary of waste at current state	Be able to identify the reasons behind the low productivity and identify the root cause of each reason. Be able to define the opportunities and areas for improvements. Design the solution-matrix for improvement. Understand the losses due to the conventional concept and current state set ups. Understand buyers’ future requirements and how it would affect badly current state as well as understand the needs in order to meet the buyer future requirements.
Toyota Production Methodology	- Why Toyota Production Methodology? - The 4 rules of Toyota - Waste Identification and classification - Human systems of the Lean organization - In factory approach versus In market approach: Costing formula	Comprehend the 4 rules of Toyota that lead to stabilize the manufacturing process and align the workers and staffs to the corporate objectives. Realize the mistakes in traditional costing formula and understand how Toyota has managed in designing and achieving their unit cost.
Identifying Waste	- Categories of Waste related to the garment industry - Value Stream mapping - Operations Scanning and process razing - Manufacturing clean-up activities	Classify what is waste and what is not or value added or none value added. Comprehend the application of the value stream mapping, operations scanning and process razing that lead to identify the waste.
Cellular Manufacturing	- Preparation and Planning - Cells designs - One Piece flow Team - Development calendar	Re-organize operations breakdown as per the flow not the process. Understanding the structure and procedures of the team. Formulate the teams and methods of selection. Be able to determine the number of members within the team Designing cells Set a training and development calendar for the team
Supporting Strategies & Concepts	- Takt Time - Pitch - One Point Flow - Kaizen blitz - Balanced Flow - Workplace Organization - 5S Continuous Improvement-Kaizen - Quick Changeover - Pull Concept and Kanban - Quality at the source & Mistake proofing	Comprehend the development and the application of the lean tools on your own operation and how to sustain them.
Point-of-Use Systems	- Requirements at the source - Multi functional teams -Visual Controls	Why teams are important at each level of the process and what are the benefits? Understanding the steps of realizing and implementing visual control systems and what are the benefits? The data required
Lean Road Map	- Lean Forum - Engineering Functions in Lean environment - Implementation steps -Keys success to lean Journey	Learn about how to manage lean project including the steps to follow through a lean forum, role and mission. Understanding the new role of the engineering department in designing the values from door to door.

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Course Code	:	LM
Course Duration	:	35 hours - 5 Full Days
Course Fees	:	Deposit US$ 80 per person (refundable upon completing 85% attendance)
Translations	:	Khmer & Chinese translation available
Pre Requisuite	:	Basic understanding of the manufacturing supply chain. High awareness of related – elements to low productivity. Acknowledgeable of business