Designing Lean Manufacturing Cells

 

The following 1-day workshop on “Designing Lean Manufacturing Cells” is being presented at various locations throughout the U.S. and Canada. The workshop can also be structured into 1 1/2 to 2 hour weekly interactive internet sessions conducted over several weeks.  The seminar content is drawn from the experience gained by The Sims Consulting Group, Inc. (SCG) and the seminar’s presenter, Ed Phillips, managing director of SCG.

 

Ed has performed consulting and training projects for many well-known companies including Alcoa, Apple Computer, AT&T, Canon, Caterpillar, Cummins, Ford Motor Co., General Electric, Gillette, Hewlett-Packard, National Steel & Shipbuilding, Nike, Pratt & Whitney, Seagram, Sears Roebuck, Sony and dozens of small to medium size companies.  He has conducted world-class manufacturing and productivity improvement projects throughout the U.S. and in Canada, India, Malaysia, Mexico, Russia, Singapore, Spain, and Southeast Asia.

AGENDA

 

Introduction To Lean Manufacturing and Cells

•     Cell characteristics and types

•     The 7 major categories of waste

•     Recommended reading

 

Product vs. Process Focused Manufacturing

•     What are the major differences?

•     Key characteristics of each approach

•     Pros and cons of cellular manufacturing

•     Positive results and level of importance

•     Focus on the customer

 

Example Results

•     Typical results (World Class Conversions)

•     WIP reduction

•     Lead time reduction

•     Materials handling improvements

•     Product velocity/throughput

 

Inventory Carrying Costs

•     High costs associated with carrying excessive inventories

•     Typical inventory turn ratios

 

Time and Value Added Considerations

•     Problems with traditional approaches

•     Optimizing process flow and value added

•     "Time" based competition

 

Importance of Batch Size -

Single Piece Flow Example #1

•     Batch size effect on speed and

      inventories

•     Importance of set-up reduction

 

Example Problem #2 - Reducing Manufacturing Lead Time from 4 Days to 2 Days

 

Value Stream and Value Network

  Mapping Considerations

 

A Step-By-Step Planning Approach

•     Developing the cell success attributes

•     Typical planning steps

 

Macro (Block) Layouts First!

•       Typical pattern of procedures

•       Data gathering

•       The 3 "A" s of plant layout

•       Analyzing material flows and internal

        materials handling

•       Ranking schemes and relationship diagrams

 

Example Problem #3 - A “Walk Through” Case Study

•       Development of block layouts with logical cell locations

 

Kanban Considerations

 

Team Considerations

•       The 3 "P"s (issues) of cellular manufacturing

•       Cell participation personalities

 

Production Line / Cell Balances

•     Importance of cycle/takt time and line balancing

•     Precedence diagrams

•     2 methods for determining line station sequence

 

Example Team Problem #4

•     Establishing a graphical balance

 

Equipment Reliability Considerations

 

Example Team Problem #5

•     Team participation Problem

•     Apply learned techniques to determine/ design cellular layouts - team problem

 

Methods Improvements

•       What to look for - a checklist

 

The registration fee is US$395 per person. For the dates, times and locations nearest you, please call 1-740-654-1091 or contact us via our website contact us page.