Lean Mastery for Manufacturers

Course Benefits

Improve your productivity by 25% to 40%
Reduce your manufacturing space by 50%
Reduce your inventory levels to a few days supply instead of a few months supply
Improve cash flow generation through lower inventories and lower investment
Virtually eliminate defects while improving product quality and reliability
Reduce lead time and improve on-time shipments performance
Design products that use simplified manufacturing techniques and that have Six-Sigma quality levels incorporated within
Have everyone in the organization involved in a continuous improvement activity permanently
Reduce your monthly accounting close to two days instead of two weeks
Run your machines for months or even years without unscheduled downtime
Reduce your set-up times and produce smaller and more frequent lots
Have a facility that is a showcase and can be used as an effective marketing tool

Course Overview

Lean Mastery Certificate training is an intensive six day program covering the elements, rules and tools needed for a Lean Enterprise.

Course Content

Introduction to Lean Enterprise. A history of Lean Enterprise and the need for change
Lean Elements, Rules and Tools. A comprehensive review of core Lean Enterprise concepts
Eliminating Waste. Detailed review of the types of waste that exist in all processes and the barriers encountered when attempting to eliminate waste
Kaizen. The engine that drives the transformation of traditional business processes to Lean Enterprise and the vehicle for continuous incremental improvement
Value. Determination of Value as the critical starting point for the Lean transformation as well as ongoing continuous incremental improvement

External Customer
Internal Downstream Customer
The customer of an external supplier

Value Stream Mapping. Understanding how to map the Value Stream for the entire Lean Enterprise and how to distinguish between value added and non-value added processes
Flow. Demonstration of the benefits of single piece flow versus traditional batch-and-queue manufacturing processes

Takt Time
Maximum Rate of Production
Balancing a Line
Spaghetti Charts
Straight Lines vs. U-Shaped Cells
Rabbit Chase
Standard Work
Curtain Operations
Identifying Process Variations
Location of Parts

Pull. Introduction to the Kanban system for inventory replenishment
- Kanban
- Point of Use Inventory Storage
Perfection. Methods to employ product and process designs to improve overall quality and reduce manufacturing costs
- Poka-yoke
- Design for Manufacture and Assembly
Visual Workplace. Explanation of the Visual Workplace, and how can it be used to enhance productivity, pursue perfection, maintain a clean and safe workplace and extend the useful life of equipment
5S. Comprehensive review of methods used to provide a clean and safe workplace and reduce overhead costs associated with plant maintenance and equipment
Total Productive Maintenance. Detailed review of TPM concepts and autonomous maintenance programs to lower overhead costs and extend the life of equipment
SMED (Quick Change). Introduction to the benefits of quick-change concepts involving tooling and production line changeovers
Cost of Quality. Review of the types of quality costs and who in the company is likely to influence or control those costs
Lean Enterprise and Six-Sigma. Introduces Six-Sigma and explains the importance of sequencing and blending Six-Sigma and Lean Enterprise programs
Lean Metrics. Key metrics and methods used to report continuous incremental improvement
The Lean Transformation Plan. Issues to be considered when planning a Lean transformation

Registration Information

Course Fee

$1,999 standard list fee per person

Instructor Brian Furlong

Brian Furlong is the Executive Vice President for Program Development with Lean Enterprises, Inc., and is co-author of the acclaimed Lean Mastery WBT course. He is a seasoned, senior executive with 30 years experience in manufacturing and finance. Brian has worked for major multi-national companies such as Emerson, Westinghouse, Invensys and National Westminster Bank.

Throughout his career, he has developed an in-depth knowledge of a wide variety of manufacturing and administrative processes. As a former VP of Operations, he has managed multi-site domestic and international locations and has directed projects to start-up plants in England, Ireland, Thailand, and Mexico. Brian has also completed acquisitions in England, China and India.

He is a passionate advocate of Lean Enterprises, having successfully completed transformations in numerous facilities in the Unites States, Mexico, Asia and Europe.

Additional Information

Rufus Hudson at 330-941-2468 or email at rghudson@ysu.edu

Michael J. Glonek at 330-941-2467 or email at mjglonek@ysu.edu

Payment by Visa, Master Card, or request to bill employer (letter or authorization must accompany registration)