About This Course

The objective of this course is to explain lean methodology and how to apply tools to optimize robotized shop floors.

We will have an overview of the basic items for optimizing automated manufacturing sites from a management point of view as well as explaining the most common tools and how those tools should be implemented. We will focus on the steps to follow the application of this methodology.

Based on current industry principles, techniques and tools we will understand how to reduce waste, creating customer value and seeking continuous process improvements with as little resources as necessary.

We will understand why employees ’engagement has remained a major challenge in lean as a quick overview on the techniques used to increase it.

Although this course is on a non-expert level, we will also comment on trends in continuous improvement ( it is a never-ending strive for perfection in everything you do).

Contents

The course is organized in 4 blocks:

1. As a start we will begin by understanding the concept of lean manufacturing in industry, how to identify different kinds of wastes (MURA, MUDA, MURI) as well as an overview on the most typical tools applied of the industry to optimize process:

   • 5S methodology. We will analyze why 5S is designed to decrease waste while optimizing productivity through maintaining an orderly workplace and using visual cues to attain more consistent operational results.

   • Pull systems. We will understand why this kind of system allows you to start new work only when there is customer demand for it and how that allows you to reduce overhead and optimize storage costs.

   • SMED. We will understand why we have to reduce setup times to ensure that we have the flexibility with our machines to run smaller batches helping us to smooth out our production and make things more flexible. We will revise a famous example

   • Lean Maintenance. We will show how to apply lean methodology in the realm of asset maintenance and repairs.

2. On block 2 we will revise and analyze the methodology VSM (Value stream mapping) and the keys to apply it successfully. We will focus on different steps that you have to follow in your organization to create a visual guide of all the components necessary to deliver a product or service, with the goal of analyzing and optimizing the entire process.

3. Block 3. We will understand the importance of employees ’engagement, from managers to operators, and will have an overview about some techniques, for example quality circles or Employee Suggestion Schemes

4. On block 4 we will establish a framework on how to apply continuous improvement for process optimization with 3 different classic methods,

   • Theory of Constraints.

   • Root Cause Analysis.

   • PDCA method.

   The key to success is based on never-ending striving for perfection in everything you do.