Lean 100 - Manufacturing Principles with Busy Blender Simulation

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1 day(s) , 8 instructional hours

About This Event:

The same lean operating principles that increase efficiency and productivity in assembly-based factories also work in the process industries, and this version of Lean 100 is tailored to batch- and continuous-flow processes: e.g., the production of paints, soaps, films, plastics, pharmaceuticals, chemicals, etc. Learn principles used by world-class manufacturers and learn how to engage your entire workforce to produce top-quality products with minimal wasted time, effort, and material. Learn to involve workers in making production smoother from start to finish, so your business performs at its peak.

The course combines lecture and hands-on activities with three rounds of simulations that reinforce the instruction in the tools and concepts. The simulation is a batch-and-queue mixing and blending operation. It includes both factory functions, with batch recipe weigh-ups, screening, QC inspection, filling, packaging, maintenance/equipment calibrations, as well as office functions. The simulation offers multiple levels of issues and changes, including the transition from batch to flow/pull, product quality variation, raw material impurities, measurement system errors, etc. Financial results are compared after each round to see the true financial impacts.

Recommended For:

This course is designed for engineers, manufacturing managers, and production supervisors. No previous experience is required, but even experienced staff will benefit from this course. You will walk away understanding the power of lean manufacturing and how to begin the implementation process.

Topics Covered Include:

The eight wastes
Standardized work
Workplace organization (5S)
Visual controls
Quick changeover
Batch size reduction
Point of use storage
Total productive maintenance (TPM)
Overall equipment effectiveness (OEE)
Pull systems
Kanban
Takt time
Value stream mapping
Quality at the source
Root cause analysis
5 why's
Capability analysis

Instructor(s):

Our lean delivery team features experts with a combined 100 years of experience in a variety of industrial and commercial settings. Those who teach the Busy Blender version of Lean 100 have generally have extensive experience in process industries.