Contact Deb Wallace at TMAC (817)272-5922 or go to www.tmac.org for more information

Automation & Robotics Research Institute The University of Texas at Arlington7300 Jack Newell Blvd., South Fort Worth, TX 76118

(817)272-5922 fax (817)272-5977 website: www.tmac.org

LEAN ENTERPRISE SERIES

Featuring Interactive Simulations & Case Studies…

Being offered At The Hogan Center, 2915 LBJ Freeway, Ste 152, Dallas, TX ..

Registration: 7:30 -8:00 a.m.Classes begin at 8:00 a.m.

Courses priced at:

•Lean 101 $ 395.00

•Value Stream Mapping $345.00

•Take a third class with Lean 101 & Value Stream mapping for $995.00

•Take a fourth class with Lean 101 & Value Stream mapping for $1295.00

•Take a fifth class with Lean 101 & Value Stream mapping for $1575.00

•Complete Series ( six classes ) for $1850.00

a NIST Network MEP Affiliate

Lean Manufacturing provides a systematic approach to reducing costs and lead time by continuously eliminating non-value added activities.

The manufacturing paradigm is shifting. Lean techniques were created by Henry Ford and perfected by Toyota. Its philosophy is catching on with today’s high performance firms. It promotes continuous improvement, committed management and empowered employees. By implementing Lean techniques at every level, managers are able to create Lean Enterprises that are increasing the gap between winners and losers.

Basics of Lean is the first step to learning the principles of lean manufacturing. The course is a mix of classroom and live simulation. Participants begin by manufacturing simulated circuit boards or model planes in a traditional manufacturing setting. The results of the first simulation round will provide the setting for continuous improvement applying lean manufacturing principles.

Participants will walk away understanding the 9 wastes in manufacturing. A mixture of lecture and hands-on simulations teach lessons in standardized work, workplace organization, visual controls, set-up reduction, batch size reduction, point of use storage, quality at the source, workforce practices, and pull systems. Each designed to eliminate waste in the manufacturing process. Full Day.

Value-Stream Mapping visually describes the flow of material and information through a manufacturer’s entire production system. This allows for better understanding of the complete process. By graphically portraying the process, one is able to see exactly where value is added and value is lost. The ratio of value added to total lead-time is figured by documenting the current lead-time, inventory levels, and cycle times. By putting all of this down on paper, the manufacturer creates a road map.

This visual representation of a process allows an operator or a manager to immediately see where costs can be reduced and improvements can be made. This road map can be used to design a vision for the future of the manufacturing process. The future vision is one that streamlines inventory, reduces waste, and cuts production time. It is a simple tool that is the first step to Lean implementation. Half Day.

5S/Workplace Organization teaches how to transform a factory into a place where thousands of messages concerning product quality, productivity, schedule, and safety are accurately and rapidly delivered every day. Participants learn methods to implement specific, easy to access visual systems to enhance communication and productivity. This course conveys the 5S + 1 methodology, and contains case histories and visual examples from companies that have successfully applied this methodology. Course participants go away with knowledge of what visual order is and what the visual workplace looks like. Students learn how these concepts function on the production shop floor. The course teaches how to deal with resistance, develop checklists and use a process map to drive the process. In addition, hands-on troubleshooting of visual challenges is included in the class. Full Day.

Cellular / Flow Manufacturing Cellular/Flow Manufacturing is the linking of manual and machine operations into the most efficient combinations to maximize value-added content while minimizing waste. Many times this requires workstations that are setup next to each other in the shape of the letter U. This is where the term cell originates, as each production line becomes its own individual cell. With the creation of these cells, products begin to flow through the manufacturing process more efficiently and maximize the contributions of the workforce.

 Pull / Kanban System - This Pull / Kanban system is a method of controlling the flow of resources by replacing only what has been consumed. This system is dramatically more efficient than the traditional storage and replenishment plan seen in most of manufacturing. A Pull / Kanban system relies on commitment from the manufacturer and the manufacturing team to be successful. It is a visually driven system controlled by employees.  How does a Pull system work? A pull system operates on the premise that no materials will be produced until there is a need from the consumer. The system does not run on economic forecasts, but on current customer demand and is supported by point-of-use material storage and the balancing of lot sizes with capacity.

Setup Reduction / Quick Changeover -  Most manufacturers spend a large amount of time setting up machines for a process or changing over machines to perform a new task. During the time spent retooling the machines, valuable production time is lost as machines sit idle. Setup reduction and quick changeover is the concept of reducing the time lost to setting-up and changing-over to less than ten minutes with the entire process requiring just one touch. These goals may not be reached right away, but through continuous and breakthrough improvement, a manufacturer will eventually see results that save time and money.

For details and availability, contact the Hogan Center.