N90400 Operations Management

• Learning by doing the key components and the elements of each Lean component which will allow you to apply the learnings immediately
• Understanding how Influence your executive team to take the initial implementation decision and become an active participant in Lean Thinking implementation plan
• Develop the courage to experiment with the tools and techniques to build a Lean Thinking system with the potential to transform your organisation

Operations Management

Lean Production Course

1. Introduction

• Why “Lean Manufacturing” today and tomorrow?
• Lean Manufacturing origin
• The Toyota Production System

2. Traditional approach Sales Forecast, Plan, MRP,  push system

• Lean Manufacturing Game I (traditional factory)
• First run: traditional approach
• Lean Manufacturing Game I (traditional factory): Analysis of the result and discussion and VSM “as is”

3. Lean Production approach: Lean Production Basic Tools

• Basic lean principles: Create value for the costumer, eliminate waste
• Flow  production (“make the material flow”)
• Pull production (Kanban)
• Value Stream Mapping (VSM)
• VSM application : “as is”
• VSM  application :  Traditional factory “as is” and possible improvement
• VSM “to be”
• Lean Manufacturing Game II
• Lean Manufacturing game II conclusion

4. Lean Production approach: Lean Production improvement Tools

• Setup reduction (SMED )
• Production leveling (Heijunka)
• 5 S (examples)
• Kaizen: Kaizen Events,  Kaizen day by day Management and Tranforming kaizen at Toyota
• TPM
• Lean Manufacturing Game III
• Lean Manufacturing game III conclusion

5. Lean Production approach: Lean Organization Tools

• Lean Product Development
• Lean Office
• Time based management
• Target cost management

6. Lean Production approach: Change Management  Tools

• Lean Manufacturing and Human Resources
• Lean culture vs traditional culture: Japanese culture, Toyota culture
• Movie Gung Ho (1986) When a Japanese car company buys an American plant and must mediate the clash of work attitudes between the foreign management and native labor.
• Movie de briefing
• Lean is changing the culture  
• Lean Change Management
• Lean Leadership

7. Lean Production approach: Information management Tools

• Visual Management
• Lean and MIS
• Lean Manufacturing Game IV
• Lean Manufacturing Game Conclusion

8. Module Test

Learning by doing

Evaluation test based on the lectures of course and the lean game experience