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Originally developed by QAD Inc. as part of their Distinguished Speakers Series.  

Video Based Education From Gray Research and Partners For Excellence

Lean Manufacturing: An Overview of Essential Lean Concepts is divided into four sections.

In the Overview (total time = 00:29:39), I cover some definitions of lean, its roots in the Toyota Production System, and how resource planning and lean work together.

In the next section, I focus on Value-Stream Mapping (total time = 00:41:10).  Value-stream maps help you see waste in your processes. They identify where there are inventory buildups, where there is excess lead time, and where there are opportunities for improvement in setup, yield, and processes.  By the end of this section, you will have a better understanding of how to develop and analyze a current-state value-stream map, and how to transition from the current-state to a future-state value-stream map.

I discuss pull replenishment in the last two sections: Pull Concepts (total time = 00:35:08) and Pull Implementation (total time = 01:07:04). 

Do you know the difference between a push system and a pull system? A one-card kanban system and a two-card system? I'll start my discussion of pull by answering these questions and covering other basic pull concepts. I'll then list and discuss the key steps in implementing pull for a lean manufacturing environment.

In the process of discussing pull systems, I'll show how to set pitch intervals, calculate the EPE Interval, calculate Takt time, manage variability in demand, size supermarkets, select the pacemaker process and use kanbans.

Also included: 

• Annotated Glossary - listen to me define some "lean" terms.

• Icons - the icons used to develop value-stream maps are defined in this section. I'll also provide additional commentary.

• Recommended Reading -a list of books on lean manufacturing recommended by me with commentary on my selections.

• FAQs-questions that I've been asked in class-room presentations on lean manufacturing.

• Workshops-work through the basic calculations for the EPE Interval and for supermarket and loop sizing.  

And as you'll see below, it's priced at less than half of what you'd spend to send someone to an outside seminar conducted by someone with similar expertise on this subject.  

Content:

• Introduction

• 8 Forms of Waste

• Definitions of Lean

• Toyota Production System

• MRP and Lean

• Value Stream Mapping Basic Concepts

• Understanding a Current-State Map

• Completing a Current-State Map

• What Contributes to a Lean Value Stream?

• Key Questions to Ask

• Developing a Future-State Map

• Basic Pull Concepts

• Push vs Pull

• Pull Replenishment

• Kanban Mechanics

• Kanban Cards

• Two Kinds of Kanban Systems

• Implementation – Manage Demand

• Implementation – Determine Lot Sizes

• Implementation – Identify Locations

• Implementation – Set Preliminary Supermarkets

• Implementation – Finalize Loops

• Implementation – Project Inventory Impact

• Implementation – Associate Inventory with Kanbans

• Implementation – Lay Out Signaling Mechanisms

• Operate

Use Lean Manufacturing: An Overview of Essential Lean Concepts  as a standalone education program for a group, as supplementary material to other course materials you may have access to, as a complement to live education sessions and readings, or for individual learning.  

Use it when your people come back from live workshops and seminars to reinforce their knowledge of important performance measurement concepts, and on an on-going basis for individual review and learning.  

Technical Requirements 

A PC with a DVD player running Microsoft Internet Explorer 5.0 or later, Microsoft Vista, Microsoft Windows XP, or Windows 2000 operating systems.

Click here: To Order

Pricing And Order Information

To order Performance Measurement and Assessment from anywhere in the world, enter your order using a credit card using the secure link accessed below.    Credit card processing is provided by PayPal but does not require a PayPal account.  

This course was developed by QAD as part of their Distinguished Speaker's Series.   QAD customers, currently "on maintenance" with the company can access this class at no charge from the QAD website:  http://www.qad.com/. 

Available to Gray Research and Partners for Excellence customers on DVD:  $395.00

Data DVD, pricing in US dollars:  $395.00.