INTRODUCTION FOR THE FOUNDATION OF MANUFACTURING EXCELLENCE
Welcome to “The Foundation of Manufacturing Excellence” This two-day training is designed to equip Individual Contributors, Junior Managers/Supervisors, Operation Leaders, and team members transitioning into leadership roles the essential skills to excel in manufacturing environments. Through interactive activities, case studies, and hands-on exercises, participants will explore key concepts like output management, production planning, quality control, and Lean manufacturing. From identifying bottlenecks to implementing 6S and Kaizen, this program focuses on practical tools and strategies to drive efficiency, improve processes, and foster a culture of continuous improvement.
Join us to build a strong foundation in manufacturing operations and take your leadership skills to the next level!
LEARNING OBJECTIVE
By the end of this workshop, participants will be able to:
- Understand Output Management: Learn to identify and resolve bottlenecks using the Theory of Constraints (TOC).
- Learn the Essentials to Production Planning: Gain skills in scheduling, resource allocation, and workforce agility to optimize operations Cross Trainings.
- Understand the Basic Quality Control: Use tools like Fishbone Diagrams and Root Cause Analysis to address quality issues and find root causes.
- Apply Lean Principles: Eliminate waste and improve efficiency using Lean tools like 5S and TIMWOOD.
- Foster Continuous Improvement: Develop strategies to encourage Kaizen and PDCA cycles in your team.
COURSE OUTLINE
Day 1: Output Management, Production Planning, and Quality Control
Introduction: ICE Breaker Activity “Truth and Lies”
Module 1: Introduction to Output Management
- What is output management?
- Introduction to the Theory of Constraints (TOC): Identifying and managing bottlenecks.
Activity: Bottleneck Simulation Games: Use a simple assembly line setup to identify and resolve bottlenecks in the operations.
Module 2: Production Planning and Scheduling
- Basics of production planning: Demand forecasting, resource allocation, and scheduling.
- Workforce agility and flexibility (Cross Trainings, Certifications)
Activity: Passing the ball games to simulate the operation flows and challenges
Module 3: Quality Control Management
- Importance of quality control in manufacturing.
- Tools: Fishbone Diagrams, Root cause analysis (5 Whys)
Activity: Team activities to generating the picture based on communication via verbal and text.
Module 4: Continuous Improvement Basics
- Introduction to Kaizen and PDCA (Plan-Do-Check-Act) cycles.
- Encouraging a culture of continuous improvement.
Activity: Kaizen Blitz: Teams brainstorm and implement a small process improvement based on the product assigned to each team. (Group sharing and Presentation)
Day 2: WIP, Inventory, Material Management, and Lean Manufacturing
Introduction: Energizer “Building the Bridge”
Module 5: Managing the 6Ms in Manufacturing
- Overview of the 6Ms: Man, Machine, Material, Methods, Measurement, and Mother Nature (Environment).
- Activity: Case Study on Production Issues and brainstorming possible solutions.
Module 6: Lean Manufacturing Fundamentals
- Introduction to Lean principles: Value, Value Stream, Flow, Pull, and Perfection.
- Overview of the 7 Wastes (TIMWOOD) and how to eliminate them.
Activity: Waste Walk: Teams observe a simulated production process and identify examples of the 7 wastes. (Video Simulation)
Module 7: The Magic of 6S in the World Class Manufacturing
- Introduction to 6S: Safety, Sort, Set in order, Shine, Standardize, Sustain.
- Benefits of 6S in organizing workspaces and improving efficiency.
Activity: Group Discussion on 6s in a factory and how to make the company to be a World Class Manufacturing Powerhouse
Module 8: Recap, Action Plans, and Closing
- Group Discussion Summarize Day 1 and Day 2 takeaways.
- Personal Action Plans: Participants draft 2-3 actionable steps to implement in their workplaces. Put into the Time Capsules.
- Video on Manufacturing Excellence and World Class Manufacturing
