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Lean Manufacturing Overview 130

Quality Training

Class Information

Tooling U classes are offered at the beginner, intermediate, and advanced levels. The typical class consists of 12 to 25 lessons and typically requires at least two hours of instruction time.

Class Name:	Lean Manufacturing Overview 130
Description:	This class describes the basic principles of lean manufacturing and compares them to traditional manufacturing approaches. Includes an Interactive Lab.
Prerequisites:	none
Difficulty:	Beginner
Number of Lessons:	18

Class Outline
Objectives What Is Lean Manufacturing? What Is Waste? Types of Waste Advantages of Lean Manufacturing High-Volume Lean Companies Multiple Batch Lean Companies Product Changeover Reduction of Inventory Product Flow Pull Systems Cells Reduction of Process Variation Error Detection Implementing Lean Principles The Five S Approach Continuous Improvement Summary

Class Objectives

Define lean manufacturing.
Define waste in terms of lean manufacturing.
Identify common types of waste.
Explain the advantages of lean manufacturing.
Describe goals for a lean company that produces large volumes of a few products.
Describe goals for a lean company that produces small batches of many products.
Explain the importance of reducing product changeover times.
Explain the importance of reducing inventory.
Explain the importance of encouraging continuous product flow.
Describe a pull system.
Describe a cell.
Identify sources of process variation.
Distinguish between inspection and error detection.
Explain the necessity of employee involvement.
List the activities of a Five S Approach.
Explain the importance of continuous improvement.

Class Vocabulary
batches	A specific number of the same part that moves throughout a production cycle.
cell	A U-shaped arrangement of various machines structured around the design of similar products. Cells encourage smooth product flows and use space efficiently.
CNC machine	A machine tool that uses programs to automatically execute a series of machining operations. CNC machines offer increased productivity and flexibility.
continuous improvement	The belief that an organization must constantly measure the effectiveness of its processes and strive to meet more difficult objectives to satisfy customers.
error detection	The inspection of a part before it has been completed to determine if it conforms to specifications.
error device	Any tool or process used to reduce or eliminate errors from a manufacturing process.
Five S Approach	A targeted list of activities that promotes organization and efficiency within a workspace. The Five S terms are sifting, sorting, sweeping, standardizing, and sustaining.
fixture	A special workholding device used to locate and clamp a part onto a machine tool.
inspection	The examination of a part to determine if it conforms to specifications. Inspection traditionally follows the completion of a part.
inventory	The storage of raw material, in-process parts, and completed, manufactured products. Excess inventory is considered waste.
kanban	A small card or visual tool that signals the movement of parts within a pull system.
lead time	The time spent between the original customer order for a particular product and its final delivery to the customer.
lean manufacturing	An approach to manufacturing that seeks to reduce the cycle time of processes, increase flexibility, and improve quality. Lean approaches help to eliminate waste in all its forms.
optical comparator	A sophisticated measuring instrument that projects an image of a part onto a screen to compare the shape, size, and location of its features.
processes	A set of activities that uses resources to transform inputs into outputs. Essentially, a process describes the way "things get done."
product changeover	The time it takes to tear down the setup for the current product type, prepare for next product type, and successfully produce the first good part.
product flow	The movement of products within the shop during each stage of the part's manufacturing process.
pull system	A production system characterized by smaller batches, quick responses to customer demand, and smooth product flow.
waste	Any thing or process that does not add value to a product. The goal of lean manufacturing is to eliminate waste.