Made to Order Lean: Improving Production in a High Mix, Low Volume Environment (1 Day class) Peppermill Resort, Reno, NV January 11, 2011
Suggested Reading and Prerequisites:
This workshop assumes you are familiar with basic lean terms and concepts. Since the workshop is based on Greg Lane's book Made to Order Lean: Excelling in a High Mix, Low Volume Environment, it is recommended you read this book prior to attending the workshop.
Participants receiving the most benefit are those working in a high mix, low volume environments, & Job Shops especially those companies that have already begun their lean transformation.
Description:
Globalization, low cost country sourcing and discounting are not going away and affect small and medium sized businesses just like do to the fortune 500’s. Though high mix, made to order type businesses first require an adaption of lean tools and ideologies instead of presenting the conveyor line, high volume “widget” examples, they also require linking those to growth strategies.
This workshop will help companies struggling with how to implement lean concepts when there are 100’s to 1,000’s of active part numbers produced randomly in low volumes. Discussion will be based on a simulation performed within a Make to Order environment. Most lean principals work in these high mix environments, though the tools and methods require some adaptation.
A proven overall implementation method specific for low volume and make to order businesses will be presented and related to the simulation, along with specialized applications of lean tools. This method is based on adapting Toyotas quality, volume and cost approach, though quality systems are not covered in detail as they can be implemented with approximately the same methods as those used in high volume. Job shops as well as repair/remanufacture facilities will benefit.
Benefits:
You will learn a flexible implementation method that can be utilized irrelevant of where you currently are in your lean transformation, and adaptable to the current business priorities. Specific tools adapted for high mix, low volume will be explained through examples and videos. Upon completing the course you will have a clear idea of how to improve your high variation operation and what methods you can quickly put in place.
Specific benefits include:
You will start by learning a sampling of lean manufacturing & planning tools that have been practically adapted and proven to increase profitability in high product mix and made to order environments from someone that has implemented them worldwide. Then structured tools will be introduced allowing you to lean manage in these environments instead of only firefighting.
Course Outline:
Through examples, simulations, videos and discussion, this workshop will follow these key concepts:
Part 1 (1 day workshop):
- Using the correct measurements
- Visual management (vs. industrial wallpaper)
- Made to Order Simulation
- Enhanced ABC analysis & making improvements
- Inventory level & kanban tools related to high mix
- Capacity Improvement
- Day-by-hour (combining kanban with mfg. to order) + video
- Feedback loop for pricing & labor effectiveness = new business
- FIFO boards
- Minimizing bottlenecks
- MRP working in conjunction with high mix lean
- Creating flexibility & increasing on-time-delivery with skills matrices
Who Should Attend?
Those who would benefit from attending this workshop include:
- Leaders from all levels
- Operations managers, supervisors, technical support, planners/production control and change agents
- High mix, low volume (job shops) in low growth or unprofitable markets.
- High mix, low volume organizations which find it difficult to adapt and implement lean because the methods and examples available are based on high volume applications.
Workshop Instructor:
Greg Lane Bio go to http://www.jobshoplean.org/Who_We_Are.html
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