Indicative contents

TIntroduction to Lean Operations

• The need for change
• Current industrial requirements, practioner thinking, people issues
• Lean methodologies
• Toyota production System, Ford production System, Lean thinking steps.
• Waste identification and elimination techniques
• Wastes, pareto, product flow analysis, string diagrams, cluster analysis, non value added analysis, Single minute exchange of die (SMED)
• Value stream mapping
• Current state mapping, future state mapping and implementation plans
• Lean technique
• Line balancing, yamazumi boards, 5 S, poke yoke, Kanban, visual controls
• Standardized work
• Standard operations, capacity charts, walk diagrams
• Manufacturing cell design
• Flow lines, nagare cells, standard cells, work allocation, cell layout

Recommended reading

• Books:
  1. Womack JP, Lean Thinking, 1996, Simon and Schuster I/S x 8
  2. Monden Y, Toyota Production System: An integrated approach to Just in Time 1998, Chapman & Hall I/S x 2
  3. Black JT, The Design of the Factory with a Future, 1991, McGraw-Hill I/S x 6
  4. Harrison A, Just in Time Manufacturing in Perspective, 1992, Prentice Hall I/S x 5
  5. H Hirano, 5 Pillars of visual workplace, 1995, Productivity Press I/S x 2 - little used
  6. Shingo S, A Study of the Toyota Production System from an Industrial Engineering Viewpoint, 1989, Productivity Press I/S x 10
  7. Nicholas JM, Competitive Manufacturing Management, 1998, McGraw-Hill I/S x 2
  8. D. Tapping, Value Stream Management, 2002, Productivity Inc.
  9. Rother & Shock, Learning to See, 1999, Lean Enterprise List