Introduction to Japan’s Lean Manufacturing System – MONODUKURI
Grasp the basic knowledge of lean manufacturing to increase productivity at your factory!
You have been wondering:
have been wondering:
Despite working for many years at a Japanese factory, do the field leaders or managers really understand the essence of the production management tools that are being applied at the factory?
You often hear about the Lean Manufacturing System or the Toyota Production System, but what does this system actually consist of? Is it being applied at your factory and is it achieving the expected results?
How to evaluate if the ongoing improvement activities are effective and fully implemented?
The course will provide production managers or quality managers with a general understanding of the Lean Manufacturing System, to support managers in understanding the essence and effectively applying/improving the methods and tools of Lean Manufacturing at their own factory.
* The Lean Manufacturing System (LMS) is a generalization of the famous Toyota Production System that has been well-known worldwide since the 1990s and is still widely applied today. It is considered the pinnacle of manufacturing systems - producing advanced, high-quality products at low cost. The LMS includes basic concepts:
““Zero defect” and “Producing what is necessary, when it is necessary, and in the necessary quantity”
When problems occur on the production line, the line should be stopped, and the root cause will be investigated thoroughly by continuously asking "why", then suitable measures will be taken to handle it.
Eliminating "Mura - Fluctuation, Muri - Overburdened, and Muda - Waste" that may occur in the production site can improve production efficiency.
OVERALL
- Duration:
- Language:
- Training venue:
- Training method:
3 days
Vietnamese
At client's company as required
Active learning through excercises, case study, role play and group discussion etc.
OBJECTIVES
- Understand the features of Japan’s lean manufacturing system – Monodukuri.
- Grasp foundational methods and tools of Lean Manufacturing, and apply them to improve the production management system of your factory.
TARGET
- Junior and middle managers (Manager, Chief, Supervisor etc.) of Production Department, QA/QC Department, etc.
CONTENT
Part 1: Introduction to Lean Manufacturing
- Origins of Lean Manufacturing
- Toyota’s philosophy
- Impacts of Lean Manufacturing System on production industry
- What is Lean Manufacturing?
- The Lean Manufacturing House
Part 2: Key concepts and principles of Lean Manufacturing
- Methods to increase productivity
- What is waste in manufacturing?
- Activities to reduce wastes
- 8 wastes in production
- Philosophy of Lean Manufacturing
- Principles of Lean Manufacturing
Part 3: Essential methods and tools of Lean Manufacturing
1. Foundational tools and methods
- 4M
- 5S
- Visual Controls
- Plant Layout
- Total Productive Maintenance
2. Standardize
- Standardized work
- Heijunka: line balance
- Kaizen: continuous improvement
3. Just-In-Time
- Kanban: scheduling system/ Kanban
- Continuous flow
- Takt Time
- One-touch changeover
- Multi-tasking
4. Jidoka – Autonomation
- Quality at the source
- Poka-Yoke: error prevention method
- Andon: alert system
- Problem solving
5. Everyone's participation
- Improvement activities for small groups
- Kaizen proposal system
- Policy management
Part 4: Action Plan
REFERENCES
"Introduction to Japan’s Lean Manufacturing System – MONODUKURI"
For the sample of training material please send your request to us here.