Lean Six Sigma (Quality Improvement)

Participants will learn how to increase productivity, streamline their work processes, and increase revenue through the implementation of Six Sigma and Lean Manufacturing processes.

Principles of Lean Manufacturing 101
Principles of Lean Manufacturing (with live simulation) is an overview class that provides a foundation for all lean concepts. Participates begin by manufacturing various assemblies in a traditional manufacturing setting. The results of the first simulation round will provide the setting for continuous improvement by applying the lean manufacturing principles. Participants will have the knowledge of understanding the 8 wastes in manufacturing. A mixture of lecture and hands-on simulations will teach lessons in standardized work, workplace organization, visual controls, set-up reduction, batch size reduction, point of use storage, quality at the source, workforce practices, and pull systems. Each is designed to eliminate waste in the manufacturing process.

Lean Manufacturing 101
How is it possible that small and midsized companies are cutting away so much waste and reporting phenomenal results? Many have said implementing Lean Manufacturing processes are the most positive, productive changes their businesses will see in their lifetime. As a result their companies are operating with less waste and using fewer resources to turn out quality products.
Through partnership with the Texas Manufacturing Assistance Center (TMAC), HCC Corporate College offers Lean 101. This program is an accelerated learning workshop that demonstrates the benefits of using Lean in an Order-to-Shipment environment to achieve breakthrough business performance.

Lean Champion Certificate Description
This program is tailored for manufacturing professionals leading lean initiatives who want to equip themselves with the skills necessary to be effective change gents and lean implementers. The 6 module-program consists of 3 days of simulation-based, hands-on workshops that present lean concepts, principles, tools and techniques to experience implementing newly learned lean practice sin a real factory. The program is highly interactive and experiential, not simply classroom lectures and theory. It’s practical, effective and proven.
Learning Objective: to have and in-depth understanding of the lean tools and be the change agent to implement continuous improvement projects within the manufacturing business operations.

Day 1: Module 1. Principles of Lean – Gain and understanding of the eight wastes and the Lean Principles designed to eliminate wastes in business processes. Through hands-on simulations, participants learn about standardized work, workplace organization, visual controls, set-up reduction, batch size reduction, point of use storage, quality at the source, workforce practices and pull systems.

Module 2. Value Stream Mapping Current State Part I – Learn how to map the current state of information and material flows using a case study. Participants learn to see the entire value stream for a product.

Day 2: Module 3. 5S Workplace Organization – Covers the basics of sort, set in order, shine, standardize, and sustain. Participants learn how workplace organization and standardization is the foundation for creating a Lean environment.

Module 4. Cellular/Flow Manufacturing – Discover the basic elements of Cellular/Flow Manufacturing, which include point of use concepts, workstation design, process layout, work combination and line balancing and Takt time.

Day 3: Module 5. Standard Work – Understand the elements of standard Work: Takt time, work sequence and standard WIP. The instructor will lead the class through the process for developing standard work in a work cell. Standard work is the key to standardization and waste analysis in the cell.

Module 6. Pull/Kanban Systems – Learn how to design and implement a visually driven, employee-controlled material replenishment system.