MTEC - Training Programs
Lean Manufacturing
Financial Management for Lean Value Streams
| Course | Description |
| A | Lean Accounting |
| As part of our expanding coverage of lean systems training programs, the MTEC invites you to attend a deep dive training seminar in Financial Management for Lean Value Streams conducted by Bruce Baggaley, Senior Partner of BMA, Inc. and co-author of Practical Lean Accounting. This three-day seminar will teach you how to make appropriate changes in your accounting and performance management systems to support an overall transformation to a lean enterprise. Participants should be prepared to learn to develop and apply new measurement standards to operations. Laptops and calculators will be provided. |
Lean Operational Excellence Certification Program
| Course | Description |
| 1 | The Lean Work System |
| This course defines lean operations and provides a technical foundation for the basic lean toolkit. Participants learn,through a progressive series of hands-on simulations, how lean production integrates operations structure, management systems, work strategies, and people to enhance the organization’s value creation and delivery. Participants apply the key tools that support lean transformation, including workplace organization (5S), workstation design (motion economy, ergonomics, and safety), visual control, standardized work, setup reduction, and source quality methods in a realistic scaled work cell. They also learn the key principles underlying pull systems from a production control and management perspective. They learn the functionality of different types of pull systems and the use of visual control boards. Although our lecture will keep you interested and engaged, we insure learning through hands-on exercises. These include direct application of the entire suite of lean tools at the system level using our table-top learning factory and at the workstation level where you design, document, and execute a lean process. You will experience the functionality and understand the performance of all major classes of pull systems including CONWIP through a series of discovery learning simulations. And you will design the structure of pull systems for cases relevant to manufacturing and service industries. | |
| 2 | Developing People and Organizations |
| This course explores the role of people in the lean system. A lean enterprise learns and improves. Systems within the organization must work together consistently for the people and the organization to benefit. Participants will investigate the organizational structures that guide behavior and build the cultural foundation for sustainable change. Through a series of discussions and hands-on simulations, we provide critical information about leadership behaviors, adult learning, forming and developing teams, and solving problems. Applying these principles will help leaders to create an effective workplace climate that teaches and engages team members fostering higher levels of performance and employee satisfaction. | |
| 3 | Lean System Design |
| This course defines the system architecture for creating lean operations. Participants learn how to map and assess complex operations and develop practical restructuring plans that enhance operational flexibility, work flow, and value creation while enabling implementation of lean operations management practices. Through a series of detailed case studies, participants will sharpen their “eyes for waste identification” and follow these by applying useful analytic concepts such as factory physics. The course develops a practical and systematic approach to restructuring that goes well beyond value stream mapping and addresses issues such as: product family definition and production flow analysis; cell formation; assessment of structural alternatives such a parallelism, kitted flows, and production synchronization strategies; and design of appropriate production control systems. Participants execute detailed restructuring plans in realistic exercises that build high level skills. These exercises extend beyond direct manufacturing and service operations to include restructuring of enterprise-level and transactional systems. Other topics include facility layout, work design and balance, and flex-work strategies. |
Lean Manufacturing for Managers Course Offerings
Lean Manufacturing for Manager is a series of 12 modules offered once or twice each month for 12 months. Each module is a minimum of one, 8-hour day – (two-day events may include a field trip to local plant.) All sessions are from 8 a.m. to 4 p.m. each day All events are highly interactive with hands-on activities to enhance learning.
| Modules | Description |
| 1 and 2 | Lean Overview |
| Lean Manufacturing concepts are being embraced by many industries as a systematic, focused approach to enhance productivity, profitability and effectiveness in meeting the needs of customers. A true Lean Manufacturing system can literally change the face of an organization by affecting every aspect of its operations. In fact, Lean Manufacturing concepts are all about employing a system that will eliminate waste and in turn implement and sustain change in operational methods. This in turn leads to gains in productivity including capacity, quality, and cost reduction by providing fast, structured, and massive improvements consistently over time. Many organizations fail to sustain improvements because they also fail to understand how closely the human resource component is tied to change implementation in reinventing the way the company operates. | |
| 3 | 5-S Visual Management and Workplace Organization |
| This course provides organizations with a systematic approach to visual management of resources and processes. A brief overview of the principles of Lean Manufacturing will be provided to set the framework for creating an awareness of the benefits, utilization and implementation of a 5-S visual management and workplace organization system. This will in turn provide the foundation skill set and system for further implementation of the various principles of Lean Manufacturing. This course will provide attendees with a knowledge base that will define the challenges and opportunities inherent in developing a 5-S system and a roadmap for implementing and sustaining a system to reduce waste and improve productivity and profitability. | |
| 4 | Value Steam Mapping |
| This course provides organizations with a system for truly reinventing their business. Using structured tools to map your current manufacturing, material handling, and administrative support systems provides a clear path to drastic improvements in short timeframes. A perfect combination of structured evaluation and disciplined reconstruction, value stream mapping commonly leads to increases in productivity of over 100% and reductions in floor space of over 50-percent. | |
| 5 | Kaizen Continuous Improvement |
| This course is considered by many experts to be the most valuable tool in any organization’s system toolbox. The traditional thought process that a company has a group of process and quality engineers to solve problems and improve systems is out of date and ineffective. The Kaizen principle mobilizes a company’s entire workforce by creating small cross functional continuous improvement teams. The system teaches empowerment in a very structured format and the training teaches organizations how to control this previously untapped resource. | |
| 6 | TPM Total Productive Maintenance |
| Total Productive Maintenance (TPM) is one of the most underutilized lean manufacturing systems used in industry today. A true TPM facility can literally change the face of an organization by affecting every aspect of its productivity including capacity, quality, and cost by providing fast, structured, and massive improvements consistently over time. Many organizations fail to improve because they fail to understand how closely consistent equipment reliability is tied to every aspect of their organization. | |
| 7 | Mistake Proofing |
| Error Proofing is a cornerstone of any zero defect environment. The system creates a culture focused on identifying all errors and variations affecting product quality and financial success. This systematic approach focuses on eliminating errors from re-occurring and providing immediate visual feedback of process variations to ensure a zero defect environment. Shifting focus from inspecting for quality to designing quality into the product and processes, error proofing will have a massive financial impact on your operation by eliminating errors, defects, pass through, rework, and inspection costs from your business. | |
| 8 | Standardized Work |
| Participants will learn how to apply standardized work to improve quality, improve efficiency, and right-size inventory. Standardized work is a proven method for preventing and reducing many types of workplace waste - including duplication of effort and process contradictions.
This program will provide users with everything they need to know to start applying principles and methods. Participants will hear informative presentations, share in group activities, and practice key concepts through case studies and exercises. |
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| 9 | Quick Changeover (Single Minute Exchange of Dies) |
| Reducing changeover times is a fundamental requirement of Lean Manufacturing. By understanding the principles and practices of the SMED system, organizations will be able to cut changeovers by over 50% with very little expenditure, and to single minutes with the modification of tooling and fastening systems. Single Minute Exchange of Dies can be applied to any changeover operation and aims to reduce the overall downtime for a complete changeover to less than 10 minutes.
Attendees will gain an understanding of the methodology required to achieve quick changeovers and the dramatic reduction in downtime that can be achieved, between the last good part and the first good part from the next component to be produced. A comprehensive manual and a unique changeover chart enabling individuals to immediately set up an effective quick changeover project in their own workplace will be provided. Attendees will also gain an appreciation for the competitive advantage that can be obtained by reducing changeover times as well as the massive reduction of overall inventory that can be achieved. |
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| 10 | Problem Solving |
| This course provides organizations with a system for problem solving. Just as companies struggle without standard operating procedures for manufacturing related operations, many operate without a standard system for problem solving. This course will provide attendees with a structured system for attacking problems cross-functionally, using previously designed tools and measuring systems to ensure the fastest most effective results with a continuous improvement mindset to ensure a path toward a progressive, predictive, efficient culture. | |
| 11 | Pull Production and Kanban |
| This course provides organizations with an advanced method of decentralizing its scheduling system and moving toward one piece flow production. With structured lean manufacturing systems controlling equipment, organization, and process control, pull production and kanban allows even traditional large batch size manufacturing companies to move toward a “make to order” environment at every step in the value stream. Raw materials, work in process, and finished goods will be where you need them, when you need them, and in the quantities you need them. The average organization will free up millions of dollars in cash flow. Inventory reduction, increased floor space, and elimination of obsolescence and scrap risk associated with storing large amounts of inventory will become a thing of the past. | |
| 12 | Preparing Your Organization for Change |
| Quarterly | Lean Manufacturing Overview for Managers |
| Lean Manufacturing concepts are being embraced by many industries as a systematic, focused approach to enhance productivity, profitability and effectiveness in meeting the needs of customers. A true Lean Manufacturing system can literally change the face of an organization by affecting every aspect of its operations. In fact, Lean Manufacturing concepts are all about employing a system that will eliminate waste and in turn implement and sustain change in operational methods. This in turn leads to gains in productivity including capacity, quality, and cost reduction by providing fast, structured, and massive improvements consistently over time. Many organizations fail to sustain improvements because they also fail to understand how closely the human resource component is tied to change implementation in reinventing the way the company operates. |
Tim Childs
Director of MTECsm @ SMC
33890 U.S. Highway 12
Niles, MI 49120
(269) 687-5651
(269) 782-1000, ext. 5651
(800) 456-8675, ext 5651
2009 Schedule
| Dates | Course |
| Jan. 20-21 | Modules 1 and 2 |
| Feb. 17-18 | Module 3 |
| Mar. 24-25 | Module 4 |
| Apr. 14 | Module 5 |
| Apr. 28-29 | Modules 1 and 2 |
| Jun. 16 | Module 7 |
| Jul. 14 | Module 8 |
| Jul. 28-29 | Modules 1 and 2 |
| Aug. 18 | Module 9 |
| Sep. 22 | Module 10 |
| Oct. 13 | Module 11 |
| Oct. 27-28 | Modules 1 and 2 |
| Nov. 17 | Module 12 |
