course | Lean Manufacturing Process Analysis and Improvement
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MRMC-669 | Lean Manufacturing Process Analysis and Improvement
Course Sector : Maintenance & Reliability Management
| Duration | Date from | Date to | Course Venue | Course fees | Book a course |
|---|---|---|---|---|---|
| 5 Days | 2025-05-05 | 2025-05-09 | Dubai | $4,250 | Book now |
| 5 Days | 2025-08-18 | 2025-08-22 | Abu Dhabi | $4,250 | Book now |
| 5 Days | 2025-11-17 | 2025-11-21 | Paris | $4,950 | Book now |
Course Introduction
Becoming a lean organization is not an easy feat and cannot be done overnight. The lean manufacturing process allows organizations to eliminate wasteful practices and improve efficiency. Its focus is on improving products and services based on what customers want and value.
This training course is designed to provide participants with the essential lean manufacturing processes and ways of workplace improvement using tools and techniques. This course will introduce topics such as the 5S, TPM, MUDA, SIPOC, advanced manufacturing analysis, measuring and prioritizing improvements, improvement of material flow by right plant layouts, and lean workplace improvement.
Course objective
- Gain a comprehensive understanding of the key lean manufacturing processes.
- Explore the lean manufacturing tools and their impact on Plant Productivity and Product Cost
- Choose tools and techniques in the efforts to introduce lean practices within the organization.
- Conduct analysis and periodical lean audits to check for opportunities for improvement and enhancements of lean implementation
- Obtain in-depth understanding of advanced analysis in improvement of manufacturing processes and the difference between discrete manufacturing and continuous manufacturing.
- Apply strategies and ways of workplace improvement in the organization.
Course Outline | 01 DAY ONE
Introduction to Lean Manufacturing
- Continuous Improvement
- Improvement Philosophies and Methodologies
- Principles of Lean
- Thinking Revolution
- Getting Customer Focus – Understand Value
- Understand the High-Level Process Flow (SIPOC)
- Map the Value Stream
- Improve Flow – Remove non-value-added steps and wastes
- Create Pull – Manage by fact and reduce variation
- Seek Perfection
- Manufacturing Case Study
MUDA, MURI and MURA as per Lean (Manufacturing Examples)
- Understanding MUDA
- Defects
- Overproduction
- Waiting
- Non-utilised talent
- Transportation
- Inventory
- Motion
- Extra processing
- MURI
- MURA
Course Outline | 02 DAY TWO
5S
- The 5S
- Preparation
- 1st Pillar – Sorting
- 2nd Pillar- Set in Order
- 3rd Pillar – Shine
- 4th Pillar – Standardize
- 5th Pillar – Sustain
- 5S Tools
- Red Tagging
- Signs
- Painting
- Preventive
- Promotion
- Poka-Yoke
- Inspection
- Statistical Quality Control
- Zero Defects
- Design Methodology
- Examples
- Standard Operations
- Jidoka
TPM
- Equipment Efficiency – Performance
- Equipment Efficiency – Motion Study
- Motion Study
- Value Analysis
- 5W and 2H Analysis
- 5 Why Analysis
- Worker – Machine Diagram
- Machine – Worker Ratio
- Machine – Machine Diagram
- Equipment Efficiency – Availability, Performance and Maintenance
- Equipment Maintenance – Preventive
- Systematic Preventive Maintenance
- Conditional Preventive Maintenance /Predictive Maintenance
- Equipment Maintenance – Corrective
- Urgent Repairs
- Schedule Corrective
- Autonomous Maintenance
Course Outline | 03 DAY THREE
- Reliability Centred Maintenance
- Maintenance Tools
- FMEA
- MTBF
- MTTR
- One-Piece Flow
- Multi-functional workers
- Kanban
- Levelling Production
- SMED
- What is SMED?
- Set-Up Time
- Set-Up Process
- 3 Steps SMED Process
- 1st, 2nd and 3rd Stage Set-Up Tools
- Zero Changeover
- Benefits
- Visual Control
- Workforce Optimization
- JUST IN TIME
Manufacturing Process Analysis
- The Data Analysis Process
- Data Collection in Different Manufacturing Settings
- Data Storage
- Data Analysis: Computational Techniques and Platforms
Measuring and Prioritizing Improvements
- Radar Chart – Measuring Improvements in Twenty Areas
- OEE (Overall Equipment Efficiency-Availability, Performance, Quality)
- Available Work Time
- Load Time
- Six Types of Equipment Losses
Course Outline | 04 DAY FOUR
Improvement of Material Flow by Right Plant Layouts
- Understanding Different Types of Manufacturing Industries
- Understanding Different Types of Layouts
- Four Signs and Reasons for a Need to Change the Layout
- Six-Step Process to a Good Layout
- Eight Factors Consideration for a Good Layout
- Equipment Losses
- One-Piece Flow
- Transfer Batch and Production Batch
Material Flow and Design of Cellular Layouts
- Material Flow in Assembly Lines and Mass Production
- Cell Layout Justification
- Basic Cell Design Nomenclature
- TAKT Time
- Cycle Time
- Cell Design Methodology
- Cell Design Tools
- Line Balancing
- Group Technology
- Time Study
Course Outline | 05 DAY FIVE
Lean Workplace Improvement
- Cleaning and Organizing
- Rationalizing the System
- Improvement Team Activities
- Reducing Inventory
- Quick Changeover Technology
- Method Improvement (Motion Study)
- Zero Monitor Manufacturing
- Coupled Manufacturing
- Maintaining Equipment
- Time Control and Commitment
- Quality Assurance System
- Developing Your Suppliers
- Eliminating Waste
- Empowering Workers to Make Improvements
- Cross-Training
- Production Scheduling
- Efficiency Control
- Using Information System
- Conserving Energy and Materials
- Leading Technology
BOOST’s Professional Attendance Certificate “BPAC”
BPAC is always given to the delegates after completing the training course,and depends on their attendance of the program at a rate of no less than 80%,besides their active participation and engagement during the program sessions.
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