Lean Manufacturing Practitioner Training

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Lean

Manufacturing

Practitioner

Training

kpmg.com/eastafrica/mc

Eliminate waste

and maximize

customer value

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2 | Lean Manufacturing Training Course

Lean Manufacturing Practitioner Training

Lean Manufacturing is a way to eliminate waste, reduce cycle time and improve efficiencies in a manufacturing environment. Lean focuses on flow, the value stream and eliminating muda, the Japanese word for waste.

Lean manufacturing is the production of goods using less of everything compared to traditional mass production: less waste, human effort, manufacturing space, investment in tools, inventory, and engineering time to develop a new product

Many manufacturing organizations waste 70%-90% of available resources through improper management of material, time, information, idle equipment, and inventory. Lean manufacturing offers tangible solutions in an effort to drastically cut this percentage of waste, improving quality, productivity and profitability in organizations.

The fundamentals of lean manufacturing practitioner training embrace the identification and elimination of waste throughout the entire value chain, ultimately resulting in a more efficient manufacturing environment.

KPMG’s three day training course provides an in-depth coverage of Lean Manufacturing

technologies and how each practice is linked together and applied to a corresponding business goal – it contains numerous real-world examples based on production challenges in a variety of industries.

The bottom line benefits to be addressed include lower production costs, higher profits, superior quality, and shorter order to deliver time, lower inventories, greater flexibility and improved response to changing customer demand. Guidelines for achieving these benefits are included. KPMG’s Lean seminar explains why lean manufacturing works and clarifies the underlying

philosophy by focusing on strategic outcomes rather than just tools. After successfully completing this seminar, participants will be able to apply Lean manufacturing appropriately to their own companies.

Who should attend?

This course is designed for:

• Manufacturing and Operations managers, production supervisors, project teams, material planners, maintenance staff, purchasing professionals and hands-on line staff, functioning in key areas including, quality engineering, supplier management, cost accounting,

consultants and anyone tasked with manufacturing improvements.

• Diverse types of industries in manufacturing environments including Electronics, Computers, Telecommunications, Medical Device, Healthcare, Fabricated Metal and Machining, Plastic, Chemical, Pharmaceutical, Food and Beverage, consumer goods manufacturers and others to enable them apply the best practices and leading tools and techniques of Lean to their processes in all functional areas.

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• Lean manufacturing concepts

• The philosophy of Lean Manufacturing • The science of Lean Manufacturing • Bottom line benefits

• Common misconceptions of lean • Understanding versus imitating lean

organizations

• Value stream mapping • Spaghetti diagrams • Operational stability • Minimal cycle time

• Identification and elimination of waste • Robust product and process design • Supplier involvement

• Visual factory

• Level, sequential production (Heijunka) • Lean supply chain management

• A ten-point roadmap

• Manufacturing as a management strategy

• Handling resistance • Lean Production flow

• Goals and performance measures • Assessing today’s factory

• Reducing lead time • Continual Improvement • Kaizen events

• Point of Use Logistics • Reducing inventory

• Total productive maintenance • Standardized work

• Continuous material flow • Pull production control • Mistake-proofing • Leading change

• Avoiding common traps • 5S+S Philosophy

• Rapid improvement

Course Approach

KPMG’s training program for Lean Manufacturing Practitioners is conducted in a dynamic environment using interactive simulation, lectures, selected hands on exercises and quizzes

including discussions of actual case studies of successful lean performance improvement, and the most current tools and techniques available.

Many Lean manufacturing initiatives fail because people don’t know where to start or how to sustain the improvements. KPMG’s Lean Manufacturing Practitioner training program provides participants with a structured approach to initiating and managing Lean supply chains and processes across diverse manufacturing environments. By focusing on reducing waste and

improving flow in manufacturing organizations, Lean manufacturing produces just what is needed, when it is needed with no additional labour, costs or time, resulting in bottom line savings.

KPMG’s Lean Manufacturing Practitioner Course Outline Key Learning objectives and outcomes

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Training Program Schedule

DAY 1

1. Introduction to Lean Manufacturing / Lean Principles

• Introduction to Lean • History of Lean • Lean thinking

• Goals of Lean manufacturing strategy • The Toyota Productions System (TPS) • Introduction to Six Sigma

• DMAIC and Lean

• The five (5) lean principles • The Lean culture

• Lean concepts and its goals • Understanding eight (8) Wastes

Manufacturing

• The building blocks of Lean Manufacturing

2. Introduction to Lean Manufacturing tools

• Lean as a total system and the phases of lean

• Planning and assessment, Value Stream Mapping

• Hoshin planning, PDCA, A3, Kaizen • Cause and Effect Diagram, FMEA • Stability, 5S, Visual Controls,

Standardized work

• Total Productive Maintenance, Poka Yoke • Continuous Flow, Kanban, Point of Use • Work Station Design, Cellular Flow • Synchronous Flow, Multiple Value

Streams

• Batch Size Reduction, Quick Changeover, SMED

• TAKT-based Production, Supermarkets, Factory Floor Layout

• Production Leveling, Pull systems, Heijunka

• Every Product Every Day, Make to Order • OEE

• Lean Maintenance • SIPOC

• Manufacturing Resource Planning (MRP)

DAY 2

3. Produce Only as Needed

• Value Stream Mapping to improve operation efficiency

• Reducing production lead time • Small lot, mixed and level production • Pull production control

4. The Need for Process Improvement & Standardisation

• Facilities layout for efficiency and flexibility

• Cellular manufacturing with small, flexible machines

• Synchronising and balancing processes • Multi machine operation

• Autonomation • Standard Operation

5. Problem Solving, Error Proofing & Supporting Techniques for Lean

• Graphical problem solving tools

• Using basic lean problem solving tools and techniques

• Plan, Do Check, Act (PDCA) problem solving approach

• 5S – Workplace organisation • Visual management techniques • TPM – maintaining and improving

equipment

• Set-up Time Reduction to improving Machine Uptime

• Target zero defect through poka-yoke • Inventory reduction

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DAY 3

6. Extend Lean Suppliers and Customers

• Invest in suppliers and engage customers

• Supplier selection and relationship • Supplier location and delivery schedule • Lean Leadership & Implementation • How to deploy Lean in an organization • How Lean links with Six Sigma DMAIC • How to develop Lean Leadership • Facilitation for Lean

• Change Management in a Lean environment

• KPI’s measuring success

• Quantifying the benefits of Lean • Building a Lean team

• Lean Culture and what it means

• Simulation to show the benefits of Lean and how to use them

• Invest in People • Teamwork

• Multi-skill workforce

• Small-group improvement activities

Upon successful completion of the training and passing on open book exam, the delegates will be awarded certificates of completion in Lean Manufacturing Practitioner.

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Course Facilitator’s Profile – Joseph P. Muga

This interactive workshop cutting across various sectors and manufacturing processes will be facilitated by Joseph P. Muga, a Certified Lean Six Sigma Master Black Belt with over 25 years global experience with KPMG Internationally in Los Angeles, USA and currently as an Associate Director in KPMG East Africa. He has worked with some of the world’s major manufacturing and service companies where he has trained and implemented Lean and Lean Six Sigma transformation strategies.

His lean six sigma implementation and training experience spans global companies such as Honda, GE, Mitsubishi, Sanyo, Pentel, Tobutsu, Hitachi, Boeing, Apple, Samsung, Panasonic, Yamaha, Verizon, Nestle, American Hospital Supplies, Burlington Northern/Santa Fe Railways, Bank of America and many others.

Other qualifications include Bs. Industrial Engineering, MBA, PhD in International Business & Developmental Economics, Certified in Production and Inventory Management (CPIM), Certified Trainer by APICS and adjunct Professor of Lean Six Sigma and JIT/TPS, California State University.

Venue: Serena Hotel, Nairobi Dates:

Lean Manufacturing Practitioner Training: 11 -13 August, 2015

Time: 8.30 am - 4.30 pm

Course fees: Kshs. 65,000 (inclusive of VAT, meals and Course materials) For more information and registration contact:

Catherine Mutuma Tel: +254 20 2806000 Mobile: +254 709 576 488 Email: [email protected] Or: Purity Mutuku Tel: +254 20 2806000 Mobile: +254 709 576 484 Email: [email protected]

Visit our website: www.kpmg.com/eastafrica KPMG Kenya

8th Floor, ABC Towers Waiyaki Way

P O Box 40612, 00100 GPO Nairobi, Kenya

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