Lean for Job Shops Training

Unit 1 Adapting Lean to Job Shops

Lesson 1 | Does Lean Really Apply?

• Appreciate the Realities that Job Shops must contend with.
• Be aware of the consequences of those Realities.
• Realize that Lean approaches can be modified and adapted to deal with Job Shop Realities.

Lesson 2 | Lean Job Shop Terminology

• Define key Lean manufacturing terms.
• Describe vital Lean tools.
• Be familiar with additive Lean techniques.

Lesson 3 | Wastes in Job Shop Terms

• Identify the seven wastes.
• Explain value-adding versus non-value adding.
• Define value from the customer’s perspective.
• Briefly describe how each of the seven wastes detracts from the value of a process’ output.

Lesson 4 | Linking Realities to Wastes

• Associate Job Shop Realities with the Seven Wastes.
• Uncover patterns of how the effects of Job Shop Realities lead to Waste.
• Discover common themes of the effects and the corresponding impact on Waste.
• Recognize potential root causes of the common themes.

Lesson 5 | Preview of the Means

• Understand that Lean practices can be adapted to a Job Shop environment by developing a compelling Message, building Momentum and making structural changes (the Means.)
• Become aware that the Means can be a combination of the 5S’s, Set-up Reduction, Workflow/Layout adjustments, TPM and Visual Workplace practices.

Unit 1 Challenge

• An assessment of the learner’s progress in this unit.

Unit 2 Lean Job Shop Practices

Lesson 1 | Message, Momentum and Means

• Become familiar with how a three-phased approach (Message, Momentum and Means) can be used to adapt Lean practices to a Job Shop environment.
• Understand how the “Means” represent a series of interdependent action plans creating a robust approach to Lean.

Lesson 2 | Embrace the 5S’s

• Identify what each of the 5S’s stands for and how it helps an organization reduce waste.
• Understand the tactics/techniques to “sort” by determining what belongs and what does not belong in a work area.
• Explain the rationale for effective storage locations.
• Describe what it means to standardize and why standardization is important.
• Identify strategies to sustain workplace organization and to prevent backsliding.

Lesson 3 | Reduce Set-Up Time

• Describe the purpose and benefits of reducing set-up time.
• Explain the difference between internal and external set-up time.
• Identify the key components of set-up reduction and explain the role each plays in reducing set-up time.

Lesson 4 | Adjust Workflows and Layouts

• Explain the linkage between layouts and workflows.
• Describe why identification of Product Families is an important step for improving layouts and subsequent workflows.
• Understand types of data needed to design effective layouts and workflows.
• Identify major issues for selecting layout and corresponding Macro-Workflow from various options.
• Understand factors to be considered to refine Micro-Workflows.

Lesson 5 | TPM Basics

• Explain how TPM aids Lean efforts and addresses wastes.
• Know the difference between Corrective Maintenance , Preventive Maintenance (PM) and Predictive Maintenance (PdM).
• Understand how the three sequential Phases of TPM build on each other.
• Realize how PdM techniques can further traditional PM practices.

Lesson 6 | The Visual Workplace

• Describe what is meant by the Visual Workplace.
• Understand the meaning of Visual Controls, Prompts and Displays.
• Appreciate how powerful visual aids, supports and alerts can be to make it easer to do things the right way and reduce waste.

Lesson 7 | Track and Improve

• Understand why it is important to measure the progress of action plans.
• Be familiar with potential measures for Lean Job Shop action plans.

Unit 2 Challenge

• An assessment of the learner’s progress in this unit.