Unit I
Lean Manufacturing – Introduction – History of Lean – Toyota Production System- comparison to other methods – The 7 Wastes, their causes and the effects – An overview of Lean Principles / concepts / tools – Toyota Production System, Tools of Lean Manufacturing- Continuous Flow – Continuous Flow Manufacturing and Standard Work Flow – 5S and Pull Systems (Kanban and ConWIP systems) – Error Proofing and Set-up Reduction – Total Productive Maintenance (TPM) – Kaizen Event examples. – Ford Production Systems, Value Stream Mapping – Current state and Future State. Building a Current State Map, Key issues in building the Future State Map – Process tips in building the map and analysis of the customer loop, supplier loop, manufacturing loop and information loop – Example of completed Future State Maps, Sustainable value stream mapping, Assessment of economical, environmental and social dimentions of sustainability –VSM 4.0 and information logistics, determine the wastes in information flow- Implementation of lean practices – Best Practices in Lean Manufacturing. Six Sigma Fundamentals -Selecting Projects – Six Sigma Statistics – DMAIC – Define, Measure, Analyze, Improve, Control. Lean Six Sigma – Four Keys to Lean Six Sigma – Delight Your Customers with Speed and Quality Improve Your Processes, Work Together for Maximum Gain, Base Decisions on Data and Facts – Five Laws of Lean Six Sigma – Case Studies.