Lean manufacturing or lean production is a systematic method originating in the Japanese manufacturing industry for the minimization of waste (Japanese: 無駄 muda) within a manufacturing system without sacrificing productivity, which can cause problems. Lean also takes into account waste created through overburden (Japanese: 無理 muri) and waste created through unevenness in work loads (Japanese: 斑 mura). Working from the perspective of the client who consumes a product or service, “value” is any action or process that a customer would be willing to pay for

  • Meaning and the applications in practice the following lean modules:
    1. Pull system
    2. Talk time
    3. Push system
    4. The production Kanban
    5. Kanban
    6. Lean
    7. Locating
    8. Poka-Yoke
    9. Set up reduction
    10. Total production maintenance TPM
    11. Traffic
    12. Transportation
    13. Universal product circle
    14. Withdrawer Kanban
    15. Project shop
    16. Re-tooling
    17. Shop floor
    18. Inverntory
    19. Internal customer
    20. In-process inspection
    21. Flow shop
    22. Fixture
    23. External customer
    24. Error prevention
    25. Error detection
    26. Cycle time
    27. Continuous Improvement
    28. Cell
    29. Celluler manufacturing
    30. Assembly line
    31. Genchi Genbutshu
    32. JIDOKA
    33. Standardize work
    34. Just in time JIT
    35. Total Quality Management TQM
    36. 5S principles
    37. PDCA principles
    38. Simple minute exchanges of dies
    39. Value stream mapping VSM

II. Quality Improvement measures: that can support the achievements of Quality improvements approach in automotive industries.

  • Benchmarking principles flow model. What is it, and how does it apply in practice to improvement measures.
  • Benchmarking principles in general. How can it be applicable in practice for process improvement.
  • Cause and effects: i.e one of the quality tools applicable during problem solving methodology.
  • Design of Experiments: what is it, how does it applicable.
  • EFQM model of Excellence/Radar principles: what is it, how does it applicable for improvement purposes.
  • Flow chart and Scatter plot/diagram: what is it, how does it applicable in practice.
  • Kaizen methodology: meaning, importance, uses, benefit, principles, objectives of kaizen e.t.c.
  • Lean management principles
  • Lean principle flow model: what is it and how does it applicable in practice?
  • MEDIC methodology: steps in process improvement, what is it, how does it applicable in practice e.t.c.
  • Pareto analysis: 20:80 principles: what is it, and how does it applicable to improvement measures in practice.
  • PDCA techniques: Plan-Do-Check-Act, Deming wheel – the importance of PDCA cycle and its application in improving the process in practice.
  • Poka-Yoke and SMED principles: what is it and how does it applicable in practice for improvement measures, how does it help in stopping defects from being escape.
  • Quality function deployment: voice of customer. what is it, how does it help to determine the improvement measures in practice.
  • Six Sigma principles: Meaning, its application:
  1. DMAIC problem solving method: how does it help in improvement measures with the application of DMAIC principle.
  2. DMADV how do we design: how does design fufill customer requirements with the application of DMADV principles.
  • Statistical Process Control SPC – Meaning, importance of SPC principle, uses and application of SPC philosophy for process improvement measures.
  • Total Quality Management (TQM) – Application of Total Quality Management in improvement approach.

Modules for productivity & quality improvement 1