Excellence Series

Lean Manufacturing Overview
42 slides
lean manufacturing - 5S - visual controls - kaizen
value streams - pull - mistake proofing
quick changeover - six sigma - theory of constraints

3 P Process
36 slides
Production, Preparation, Process (3P)
Focus on eliminating waste through Product and process design

5S and Visual Controls
43 slides
elements of 5S - workplace organization
implementing 5S - visual factory

Jidoka
31 slides
Enables machines and operators to detect abnormal conditions and immediately stop work. Build in quality at each process, autonomation.

Kaizen
44 slides
what is kaizen - history - implementation steps
kaizen blitz – roadblocks

Value Streams
74 slides
identifying value streams - value stream mapping
current & future states - unique situations
enhancing the future state - implementation – roadblocks

Pull, JIT, Kanban
68 slides
pull - the problem with inventory - just in time
kanban - one-piece flow - demand flow - standard work
takt time - production smoothing

Poka Yoke and Mistake Proofing
51 slides
what is mistake proofing - everyday examples
effectiveness and ROI - error proofing and SPC
inspection techniques - types of poka yokes

Quick Changeover and SMED
53 slides
changeover and changeover time
traditional setup characteristics
single minute exchange of dies - SMED process steps
implementation

Cellular Manufacturing
60 slides
fundamentals of plant layout - process layouts
product layouts - fixed layouts - hybrid layouts
cellular manufacturing - implementing cells
part families

Standard Work
47 Slides
Each step in a lean manufacturing process should be defined and must be performed repeatedly in the same manner. Variations in the process will create quality problems requiring costly rework or scrap.
Standard work will define the most efficient methods to produce product using available equipment, people, and material.

Theory of Constraints (TOC)
50 slides
introduction to constraints
five steps of the theory of constraints - drum buffer rope
evaporating cloud method - batch size problem
chain analogy - issues with TOC
measurements and financial impacts

Training Within Industry
51 slides
four training programs developed by TWI
the Five Needs of the Supervisor
Charles Allen's 4-point method
Preparation, Presentation, Application, and Testing
Job Instruction (JI) - Job Methods (JM)
Job Relations (JR) - Program Development (PD)

Total Productive Maintenance (TPM) and Maintenance Management
55 slides
origins of TPM - principles of TPM
autonomous maintenance - planned maintenance
process maintenance - process quality – implementation
benefits - maintenance strategy

Balanced Scorecard
65 slides
what is the balanced scorecard - why use it
fundamentals concepts -the four perspectives
measures, targets, and initiatives - issues and challenges

Competitive Intelligence
44 slides
A formalized yet evolving process to assess the industry and current and potential competitors, and to develop competitive advantage

Design for Lean & Six Sigma
91 slides
Lean Six Sigma uses Lean to increase organizational speed, combined with Six Sigma to improve efficiencies. Six Sigma applied to product design is called design for six sigma (DFSS)

Knowledge Management & Learning Organizations
91 slides
trends in knowledge management - forms of knowledge
intellectual capital - challenges - critical success factors
learning organizations - team learning

E-Commerce
40 slides
types of e-commerce - B2B - B2C
integrating with traditional commerce - security issues

Job Design, Work Measurement, and Labor Standards
56 slides
job expansion - job specialization
psychological components - incentive systems - ergonomics
time studies - work sampling - labor standards

Human Factors
83 slides
ergonomics - rewards and recognition
safety and health - effective teams

Outsourcing Strategies
64 slides
location - global strategy – logistics
relationship management – negotiation

Cost Accounting
304 slides
terms & concepts - job order costing - cost behavior
cost/volume/profit - activity based costing
profit planning - standard costs - flexible budgets
overhead analysis

Supply Chain Strategies
75 slides
strategic importance - economics – strategies
management - internet - vendor selection
benchmarking metrics - value chains – global

Capital Budgeting
60 slides
decisions - time value of money - cash flows
recovery of investment - net present value
internal rate of return - total cost
incremental cost - least cost

Facility Location Strategies
44 slides
importance - decision factors - BMW example
labor productivity - costs - rating and selection strategies

Technology Assessment
276 slide
technology management – change
technology planning & forecasting - methods & issues
lifecycles - monitoring - tools – trending

Strategic Management
200 slides
strategic thinking - the process - customer analysis
competitor analysis - strategy formulation
strategy execution

Forecasting, Planning, and Scheduling
175 slides
forecasting approaches - monitoring & control
aggregate planning - planning strategies
sequencing - priority rules - MRP - ERP – DRP

Project Management
151 slides
PM today - rapid change - project planning
management & communications - politics
organizational issues - people issues
tools & methodologies

Lean Office Overview
256 slides
lean office - 5S - visual controls – kaizen
value streams - pull - mistake proofing
quick changeover - six sigma - theory of constraints

Office 5S and Visual Controls
26 slides
elements of 5S - workplace organization
implementing 5S - visual factory

Office Kaizen
28 slides
what is kaizen – history
implementation steps - kaizen blitz – roadblocks

Office Value Streams
68 slides
identifying value streams - value stream mapping
current & future states - unique situations
enhancing the future state
implementation – roadblocks

Office Pull, JIT, Kanban
46 slides
pull - the problem with inventory - just in time – kanban
One-piece flow - demand flow - standard work
takt time - production smoothing

Office Poka Yoke and Mistake Proofing
67 slides
what is mistake proofing? - everyday examples
effectiveness and ROI - error proofing and SPC
inspection techniques - types of poka yokes

Office Layouts and Cells
43 slides
fundamentals of layout - process layouts - product layouts
fixed layouts - hybrid layouts - cellular manufacturing
implementing cells

Office Total Quality Management
97 slides
evolution of quality - what is quality - cost of quality
quality management systems - implementation issues

Office Theory of Constraints
69 slides
introduction to constraints - five steps of the theory of constraints
drum buffer rope - evaporating cloud method
batch size problem - chain analogy - issues with TOC
measurements and financial impacts

Total Quality Management (TQM)
100 slides
evolution of quality - what is quality - cost of quality
quality management systems - implementation issues

ISO 9001:2000
211 slides
quality management principles - compatibility with other systems
changes from previous standards
section-by-section review and discussion of the ISO 9001:2000 standard

Design of Experiments (DOE)
23 slides
model variables - variable targets - experimental plan
testing – analysis – effects – replicates - interactions

Statistical Process Control (SPC)
76 slides
variability - control charts - process capability
repeatability – reproducibility - gauges

Root Cause Analysis
105 slides
what is root cause – benefits
the problems solving process – examples

Six Sigma
92 slides
what is six sigma - phases of six sigma
define - measure - evaluate/analyze - improve – control
design for six sigma - green belts and black belts

Poka Yoke and Mistake Proofing
75 slides
what is mistake proofing - everyday examples
effectiveness and ROI - error proofing and SPC
inspection techniques - types of poka yokes

FMEA - Failure Modes & Effects Analysis
23 slides
what is FMEA - benefits - application - procedure – example