1. Evaluate the advantages of world class or "lean" manufacturing systems.
- Implementation of lean manufacturing through value flow. JIT prevents and eliminates waste in processes
2. Analyze the importance of corporate culture in supporting the implementation and support of lean manufacturing.
- Behavioral expectations will only produce culture change if they are modeled by a leadership team. The leadership team must be committed to the guidelines as a new way of doing business.
3. Evaluate how Deming's concept of cooperation rather than competition supports the efforts of a company to accomplish process improvements.
- Unless staff work jointly in a spirit of co-operation, each area will try to do what is best for itself, rather than what's good for the organization.
4. Model how to integrate five step problem solving with plant improvement strategies.
-Team mindset
-Define quality
- Develop cost of quality
- Solve problems
-Employ process discipline
5. Apply the five-step problem solving process to resolve manufacturing problems.
-Determine customer requirements and required space/components/costs to produce parts
6. Apply basic work standards methodology to implement lean manufacturing.
-Material used
- TAKT Time
- Sequence and work flow
7. Model how to achieve elimination of waste by focusing on goals, recognizing multiple goals, and systematically achieving those goals.
- Determine parts needed for material
- Wait times
- Inventory storage needed
- Defects
8. Formulate reasons for selecting alternative improvement methods.
- Using several alternatives gives cost effective options that can control production outputs, waste, and time.
9. Systematize how process improvements may be implemented into a lean manufacturing process.
- Process improvements are anything that can improve or make a process more efficient. They are found by talking to workers and watching the work process being done.
10. Assemble 7 types of waste in manufacturing systems.
- The 7 types of waste will be addressed by determining work defects, production, transporting, waiting, inventory, motion, and processing.
11. Assemble the 3 flows in manufacturing systems.
- determine the flow of raw material, WIP, finished goods, operators, machines.
12. Model the material and information flows identified.
- will determine all materials with a BOM along with time leads for operations, transportation and finished goods.
13. Translate the symbols used to map a product value stream.
- After developing the value stream map, symbols will be defined though processes, inventory, ect.
14. Calculate takt time and discuss its meaning in the manufacturing system.
- Calculate TAKT time for assembly between all requires shifts/processes.
15. Construct the levels of automation and proper application.
- If automation is required, the levels will be human assisted.
16. Appraise the use of Kanban and the rules for Kanban in production applications.
- Kan ban will be used to determine JIT
17. Analyze the one-piece flow concept.
- Continuous flow helps achieve JIT manufacturing by moving parts through operations from step to step with no WIP in between pieces.
18. Evaluate an actual process (or a process from an Engineering Case book), propose a plan to implement lean manufacturing into that process, and orally present the material
Develop and implement work instructions and standard work for all operations at PST (One Point Lessons POA)
Develop training process for work instructions and standard work
Using the 5-S approach to workplace organization, Improve a 5-S audit of levels one and two by scoring a minimum of 80% for each
Develop and implement a process for part identification and traceability.
Develop ground work for implementationof Layered Process Audit (LPA Process)
Brainstorm and consense on key process and product characteristics for process feedback to Progressive and score card development for NetShape (KPI's)