Lean 101: Lean Principles - TekRidge Center

Although Lean manufacturing is a well-defined process with straightforward implementation steps, it can be difficult to execute if the employees who are working on the project don’t change their mindset. That is, it is more of a culture shift than a process of following steps. It is for this reason that it is common to see the term “Lean manufacturing” used alongside “Lean thinking.”

NEPIRC’s Lean Principles class helps participants start the “thinking” part of the cultural transformation by teaching the 8 wastes of manufacturing and identifying value-added vs. non-value-added activities. This is done through a combination of classroom teaching and hands-on simulation of manufacturing processes.

Upon completion of this session, students will be able to apply an understanding of basic Lean Principles to their workplaces. Participants will also learn how to do a “waste walk” and identify corrective actions for improved effectiveness and efficiency. As a result of this class, potential workplace improvements might include reduced inventories and overproduction, better machine utilization and improved information flow and/or improved customer focus. If desired, action plans can be created to reduce waste and implement improvements at a participant’s workplace.

Companies considering Lean enterprise as a corporate initiative should especially consider having employees take this course as a foundation for further training and to gain employee support for future activities.

Outline of Lessons

Section 1

Simulation of a typical and traditional manufacturing facility. Evaluate performance metrics: completed units, cycle time, first-pass quality, unit cost, work flow, and Work In Process (WIP). Begin learning a method for identifying problems.

Section 2

Learn to recognize the 8 common wastes related to non-value added activity. Define Lean tools: Standard Work, 6-S Organization, Visual Controls, Point of Use Storage, Plant Layout and Batch Reduction.

Section 3

Learn the difference between a “Push” system and a “Pull” system. Apply a Kanban system to the simulation and compare results from all 3 rounds.

Learning Objectives

• Gain an understanding of the characteristics and benefits of a “Lean” vs. “traditional” manufacturing environment

• Learn the “8 wastes” and how to minimize or eliminate them by applying various lean concepts

• Learn how to categorize value-added vs. non-value-added activities and ways to eliminate those that are non-value-added

• See how Lean tools are applied in a traditional manufacturing environment through hands-on simulation