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Lean 101: Principles

Continual Improvement


Course Length

8 Hours

Max Attendees


Course Description

Lecture and hands-on simulations introduce standardized work, workplace organization, visual controls, setup reduction, batch size reduction, point-of-use storage, quality at the source, workforce practices, and pull systems. Participants assemble test circuit boards in a simulated manufacturing setting. Results of the first simulation round provide the setting for continual improvement applying lean enterprise principles to reduce the eight waste.

Course Objectives

  • History of manufacturing (evolvement of lean)
  • Lean definition
  • Eight wastes
  • Lean tools
    • 5 S of workplace organization
    • Visual factory
    • Plant layout
    • Batch reduction
    • Quick changeover
    • POUS
    • Standardized work
    • Pull/Kanban system
    • Cellular design
  • Benefits of lean

Course Outline

The simulations reinforce the benefits of lean by applying tools introduced during the lecture. Each of the simulation's four rounds will consist of participants making improvements and comparing metrics such as lead time, on-time delivery, quality and bottom-line profit.