Lean Enterprise Workshop
As of Tuesday, October 23, 2018

Introducing the NEW APICS Lean Enterprise Workshop Series

As more organizations decide to go lean, demand is escalating for a skilled team and system- wide approach for developing and implementing lean project plans. This course is designed to equip you with the broad knowledge and tools to map the transformation for developing a lean culture at your organization.

This workshop will allow you to:
  • Complete a self-assessment to determine your organization's readiness to implement lean
  • Gain practical experience analyzing how to incorporate lean into organizations
  • Leave with a project plan for implementing lean into your organization

The APICS Lean Enterprise Workshop Series is organized to enable you to approach and understand the lean transformation process systematically. Using scenarios from a fictitious company, Murphy's Toys, you will be tasked with finding lean solutions to a myriad of challenges. This method will provide you with the flexibility to immediately customize what you've learned and implement it at your own organization.

There are seven workshops in the series:
You will gain an overview of the many components of implementing a lean transformation in your organization and gauge your organization's readiness through a hands-on assessment.

Lean Culture
Explore the effects of a lean implementation on your employees and learn about the importance of teams. The Kaizen, a team- oriented continuous improvement event will be introduced in this section.

Value Stream Mapping
Learn about value stream mapping and this tool's value for viewing processes and determining potential areas of improvement. Draw a current state map and then learn about concepts to help you improve your future state.

Stability and Process Improvements
Learn how to improve process stability, achieve demand stability and improve manufacturing process efficiencies.

Determine customer demand, standard work, line balancing and many other tools to meet customer demand. Participants will explore the use of a heijunka system to meet customer demand through a hands-on activity.

Review the way a lean company measures and align measurements with objectives. Topics include lean accounting, inventory costs, target costs and lead time.

Learn about the long-term changes to sustain the gains made. Topics include lean design, analyzing failures and ensuring ongoing quality control and continuous improvement

Contact vp.education@apics-chicago.org . or 1-800-982-7427 for more information.

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Introduction to Lean Manufacturing

After completion of this workshop you will be able to
• Explain what a lean operation is and the benefits it provides
• Identify waste activities and understand why they should be eliminated
• Analyze a process using process flow analysis approach
• Understand popular lean manufacturing tools such as the 5 S’s, visual order and control, setup time reduction, manufacturing cells, use of takt time, standard worksheets, etc.
• List the benefits of incorporating lean concepts during the development phase of new products
• Explain what error¬ controlling devices are and how they can be used during production to reduce errors
• Understand what sigma quality concepts are, how to conduct kaizen blitzes, and why continuous improvement is important.

• Waste Elimination
• A Lean Improvement Methodology
• Leadership
• The Transparent Workplace
• Lean Process Improvement
• Lean Product Development
• Just¬ in¬ Time
• Controlling Processes
• Standard Work
• Continuous Improvement

Lean Mapping

• To introduce the basic mapping tools for lean analysis
• To understand when and how various mapping tools could be used
• To obtain a grounding on learning ¬to-¬see mapping
• To learn how mapping can be the basis of lean transformation

• Types of map used for lean
• Value¬ stream mapping
• How to identify your company’s value streams
• How to create a current state map
• How to develop other useful maps
• How to analyze a current state map and develop a future state
• A framework for lean implementation using mapping

5S Workshop

• Learn the benefits of 5 S
• Understand the definition and meaning of 5 Ss
• Learn the proper strategy for implementing a 5 S program
• Conduct 5 S exercises
• Apply 5 S principles at work

• Introduction to Lean Manufacturing
• Goal: Learn 5 S by Doing
• Definition of the 5 Ss
• Phase 1 of 5 S: Sort
• Exercise 1 – Tackle disorderliness and Lack of Cleanliness and Sorting in the Shop by Targeting Unneeded and Excess Items
• Discuss Sorting Observations/Opportunities for Implementing 5 S Projects
• Auditing a Shop for Sort
• Phase 2 of 5 S: Set in Order
• Exercise 2 ¬ Develop a New Layout for the Shop to Include Material, Equipment and Fixtures, and Location Indicators
• Discuss Set in Order Observations/Opportunities for Implementing 5 S Projects
• Auditing Set in Order
• Phase 3 of 5 S: Shine/Inspect
• Exercise 3 ¬ Identify and Develop a Plan for Shop Cleaning and Equipment Inspection/Maintenance
• Auditing Shine/Inspect
• Phase 4 of 5 S: Standardize

Process Improvement and Quality in Lean Manufacturing Workshop Objectives

• To illustrate the symbiotic relationship between lean and quality
• To appreciate the application of some quality techniques in a lean context.
• To appreciate how lean and six sigma can work together.

Workshop Topics
• Views from the Gurus
• The Lean View and Kaizen
• Problem Solving and PDCA
• Types of Defect
• Sporadic Problems: The Seven Tools and Five Whys
• Chronic Problems and Six Sigma
• Improvement Types
• Improvement Events (Blitz)
• Holding the Gains and Sustainability

Lean Scheduling Workshop

• Provide an overview of the central role of scheduling in a lean context
• Establish a framework for the implementation of a lean scheduling system
• Provide a working knowledge of core lean scheduling techniques.

Workshop Topics
• Frameworks for lean scheduling
• Relationships between lean and MRP, APS, and TOC
• Managing queues and flow
• The effects of variation (statistical fluctuation and dependent events)
• Building blocks for lean scheduling
• Eight lean scheduling ideas: (pull and kanban, takt time, runners repeaters strangers, the pacemaker, mixed model scheduling, level scheduling and heijunka, batch sizing, demand stabilization)
• A brief look at CONWIP and POLCA

Standard Work Workshop

• Understand the elements and methods of standard work
• Understand cellular manufacturing
• Conduct time observations, process capacity studies, and team activities related to standard work
• Prepare standard work documents

• Introduction to Standard Work
• Capacity Concepts
• Cellular Manufacturing
• Standard Work Elements

Lean Teams, Lean Design, and Accounting Workshop

• To provide an overview of the role teams, measurements, and design have in contributing to success in lean implementation
• To review relevant current theories on teams, accounting, and design as they relate to lean

• Team and Leadership Models for Lean
• Lean Measurements
• Lean Accounting and Costing
• Lean Design Considerations
• Modularity and Platforms



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