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Lean Master Program

Lean Master Program. Objectives & Contents. Brief background of AMC Lean & TOC in a nut-shell AMC Services Details of the Lean Master Certification Program Benefits & Credentials of the Lean Master Program. The Lean Master Program. pathway to developing Change-Agents who can increase

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Lean Master Program

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  1. Lean MasterProgram

  2. Objectives & Contents • Brief background of AMC • Lean & TOC in a nut-shell • AMC Services • Details of the Lean Master Certification Program • Benefits & Credentials of the Lean Master Program The Lean Master Program pathway to developing Change-Agents who can increase profitability Manufacturing & business solutions towards increased profitability

  3. Brief Background of AMC • Advanced Manufacturing Consultancy (AMC) is a Manufacturing Consulting company, founded and registered in Malaysia in 2001 • The company is founded by former Seagate Technology’s internal Corporate Lean Consultants. They had extensive exposure in Lean Deployment within Seagate and led the Supplier Lean Academy in Asia. Having accomplished great savings for Seagate & its suppliers they formed AMC as a leading service provider in Lean Manufacturing consulting & training in Asia and have currently expanded to wider areas of service Manufacturing & business solutions towards increased profitability

  4. Lean & TOC in a nut-shell: What is Lean Manufacturing • Lean is a leading edge manufacturing technology which aims to identify and eliminate or reduce “Lean Wastes” (non value added activities) in any manufacturing environment (regardless of size or industry) by using systematic Lean Tools. • The “Lean Wastes” are : • Excess Inventory • Maintaining excess inventory of raw materials, parts in process, or finished goods • Overproduction • Producing more than is needed before it is needed • Motion • Any wasted motion to pick up parts or stack parts • Transportation • Wasted effort to transport materials, parts, or finished goods into or out of storage • Waiting • Material awaiting to be processed or to be transported • Over processing • Doing more work than is necessary • Correction • Repair or Rework • Unutilized Human Resources • Not using operators to their maximum ability Manufacturing & business solutions towards increased profitability

  5. Lean & TOC in a nut-shell: What Is The TOC • The Theory of Constraints is a focused and proven approach of identifying what limits (constraints) a system from achieving it’s profit goals or continuously achieving higher goals and exploiting these constraints in order to achieve quantum gains within a very short period of time • Advanced Manufacturing Consultancy approaches Manufacturing Solutions by using the Theory of Constraints to identify System Limitations (Constraints) and using Lean Tools to eliminate Waste at the constraint This results in unbelievable leaps of increased Productivity and Throughput within a very short period of time Manufacturing & business solutions towards increased profitability

  6. Services Offered by AMC • Lean Consulting • Assessments & Opportunity identification • Lean Diagnostics to identify Waste • Factory Audit and scoring • Engaged with client in Lean Projects • Supplier Lean initiatives – speeding • time to respond Solutions For Increased Profitability • Constraint Busting • Identifying System Constraints & Bottlenecks • Increasing bottleneck Capacities with • Low Cost or No Cost Solutions • Training & Education • Lean Tools Training • Lean Master Certification Program • Public Seminars • Executive Boot-camps • Short Courses • Six Sigma training Manufacturing & business solutions towards increased profitability

  7. Key Services Description Lean Assessments • Diagnostic Assessment and Opportunity Identification • This service is performed typically over a period of 2 to 3 days by 2 consultants. The clients level of Lean deployment and opportunities for improvement is assessed Sample assessment radar chart Manufacturing & business solutions towards increased profitability

  8. Key Services Description Lean Consulting-Constraint Busting • Consultants work with clients to identify and improve existing bottleneck performances to meet increased demands. Projects frequently lead to huge capital avoidance for clients Sample bottleneck improvement chart Manufacturing & business solutions towards increased profitability

  9. Key Services Description Lean Education • Lean Education involves the transfer of hands on knowledge on theory and application of all the Tools in the Lean Toolbox. This is done through in-house or public training sessions. The approach taken is one of Learn-Do-Mentoring. Training includes: • Two Day Value Stream Mapping session • 5-14 day short courses • One day Theory of Constraint Boot-camps • Two day Executive Boot-camps (TOC, Lean Overview, Value Stream mapping & Change Leadership) • Lean Master Certification Program Manufacturing & business solutions towards increased profitability

  10. THE LEAN MASTERCERTIFICATIONPROGRAM

  11. The Lean Master Program Outline Total 5 Waves Spread Over 5-6 Months • Delivered Through • Class Room Theory • Simulations • Diagnostics • Shop Floor Activities • Case Studies • Projects on Real Problems Taught by Qualified Lean Masters With Long Industry Exposure Manufacturing & business solutions towards increased profitability

  12. The 5 Waves Structure • There are 4 Waves of 4 Days each • The Final Wave is graduating Case Study Wave of 2 Days • Total of 18 Days of Training & Development The Lean Master Program Outline Total 5 Waves Spread Over 5-6 Months • Delivered Through • Class Room Theory • Simulations • Diagnostics • Shop Floor Activities • Case Studies • Projects on Real Problems Taught by Qualified Lean Masters With Long Industry Exposure Manufacturing & business solutions towards increased profitability

  13. Hands-On Approach • Candidates are exposed to: • 3 Whole day class Room Simulations & several more half day simulations • 3 Video movies • Shop Floor exercises for all major tools taught • 3 Real Projects needs to be completed by each candidate The Lean Master Program Outline Total 5 Waves Spread Over 5-6 Months • Delivered Through • Class Room Theory • Simulations • Diagnostics • Shop Floor Activities • Case Studies • Projects on Real Problems Taught by Qualified Lean Masters With Long Industry Exposure Manufacturing & business solutions towards increased profitability

  14. The Trainers • They are Qualified Lean Masters • They have Industry Exposure in Manufacturing Environment for more than 15 years • They have trained and consulted small as well as Fortune 50 companies The Lean Master Program Outline Total 5 Waves Spread Over 5-6 Months • Delivered Through • Class Room Theory • Simulations • Diagnostics • Shop Floor Activities • Case Studies • Projects on Real Problems Taught by Qualified Lean Masters With Long Industry Exposure Manufacturing & business solutions towards increased profitability

  15. The Lean Master The Lean Master Graduate Will Be Trained To Become: Lean Leaders of Operational Excellence Lean Practitioners who can Diagnose & Solve problems Effective Organizational Change Agents Lean Consultants who can improve manufacturing profitability Manufacturing & business solutions towards increased profitability

  16. The Training Approach • The program is taught in a Learn-Do-Mentor approach Wave Three Error Proofing Overall Eqt. Effectiveness Total Prod. Maintenance Need to complete 1 project before next Wave 4 – 5 Weeks Later Wave Two Setup Time Reduction Visual Management Work Standardization Need to complete 1 project before next Wave 4 – 5 Weeks Later Wave One Lean Overview Change Management 5 S Manufacturing & business solutions towards increased profitability

  17. The Course Contents Wave 1 - The Compass Wave • Lean Overview • This offers a birds-eye view of the Tools of Lean Manufacturing and their effect • It is delivered through a one-day highly interactive simulation using Lego • Value Stream Mapping • It is a Diagnostic exercise which helps map what adds value and what is not adding value in the whole system • Identifies opportunities for Lean improvement • Team is made to draw clients actual value stream map • Lean Thinking Process • Theory and thought process of Lean Manufacturing and the Theory of Constraints Manufacturing & business solutions towards increased profitability

  18. The Course Contents Wave 1 - The Compass Wave • Change Management- Leading Change & Communication Strategies • A detail look into why any organizational change fails and how to Lead effective change • Methods of stakeholder communication • The Who Moved My Cheese video is showed • Shop Floor Management - 5S • The basics of Lean starts with an organized shop-floor • 5S methods are taught and shop-floor red-tagging activity is carried out • Lean Project Management and requirements • Projects are identified for Wave 1 Manufacturing & business solutions towards increased profitability

  19. The Course Contents Wave 2 • Wave 1 Projects presentation & Review • Review of actual projects completed by Lean Master candidates between Wave 1 & 2 • Change Management - Handling Resistance & Practical Filed Guide • Covers difference types of resistance people pose to change and methods of handling these • Practical assessment of clients change adaptability and strategies for effective Lean deployment Manufacturing & business solutions towards increased profitability

  20. The Course Contents Wave 2 • Shop Floor Management - Visual Systems & Standardized Work • Working towards a Visual factory where one will be able to tell at a glance “what is going on” and “what is needed’ in the shop-floor • Standardized work covers methods and strategies of repeatability in processes and shop-floor activities. It also covers importance and features of an effective SOP • Setup Time Reduction • This is a powerful tool used to reduce change-over time and setup activities such as PM, Daily Cleaning etc. • The module is taught with an exciting car tyre changing exercise and video shooting before doing actual shop-floor activity Manufacturing & business solutions towards increased profitability

  21. The Course Contents Wave 3 • Wave 2 Projects presentation & Review • Review of actual projects completed by Lean Master candidates between Wave 2 & 3 • Error Proofing • A detail study of methods and strategies of mistake proofing • Covers methods such as Red-Flag conditions, Fish Bone analysis and detail problem solving strategies • Lean Performance Metrics • A specific set of measurements which are a driving force towards speed, flexibility and predictability in an organization • Covers Measurements such as Manufacturing Cycle Time (MCT), Overall Equipment Effectiveness (OEE), Dock to Dock Time (DTD), Throughput Metrics etc. Manufacturing & business solutions towards increased profitability

  22. The Course Contents Wave 3 • Total Productive Maintenance • A structured approach to maintaining equipment to enable stable processes • Includes Machine measurements such as OEE, MTBA, MTBR etc • Addresses importance and strategies of using Autonomous Maintenance (operator involvement) in improving equipment OEE • Case Studies • Real factory problems are submitted in the form of case studies to brush problem solving skills in the candidates • Case studies will cover each of the key Lean tools taught Manufacturing & business solutions towards increased profitability

  23. The Course Contents Wave 4 • Wave 3 Projects Presentation & Review • Review of actual projects completed by Lean Master candidates between Wave 3 & 4 • Theory of Constraints & Drum-Buffer-Rope • The principles of bottleneck management and the application of the Drum Buffer Rope material managementconcept to optimize bottlenecks • Theory of the TOC thought process • The Goal Movie • The Goal Movie is a world renowned movie presentation of TOC concepts and application of the Theory of Constraints in a real factory scene Manufacturing & business solutions towards increased profitability

  24. The Course Contents Wave 4 • Material Management & Kanban Systems • Different Types and methods of Material Control and Pull System are discussed and taught • Topics include: KANBAN Types, KANBAN Quantities and formulas etc. • Lean Diagnostics • Understanding how to assess a plant, identify opportunities and decide on the specific tools to be applied Manufacturing & business solutions towards increased profitability

  25. The Course Contents Wave 4 • The Lean Roadmap • Candidates are given the right approach in deploying Lean and proliferating it throughout a plant in stages • IT Tools • a Discussion on what an IT system should provide in order to support a Lean & TOC factory • Discusses some of the drawbacks and suggestion on current IT solutions such as MRPII, ERP etc. • Case Studies & Test • Candidates are required to pass test on the various modules taught from Wave 1 - Wave 4 Manufacturing & business solutions towards increased profitability

  26. The Course Contents Wave 5 - The Graduation Wave • High Level Case Study and Problem solving • A high level case study which requires extensive diagnostic abilities and team collaboration is presented to candidates • Candidates work in small group teams (about 3 or 4 members) in solving this Harvard Business School Level case study which is based on actual factory problems • Group Presentations • Group presentation of the Case Study • Graduation Ceremony • Awarding of certificates Manufacturing & business solutions towards increased profitability

  27. Requirements for graduation • Each candidate must fulfill following requirements in order to graduate as a Lean Master • Must have attended and had active participation in all 5 Waves of the program • Active participation and presentation of case studies given during waves 3 & 4 • Complete at least 3 projects and must have shown a real improvement trend acknowledged by trainers and candidate’s management team • Passed the comprehensive Test in wave 4 Manufacturing & business solutions towards increased profitability

  28. The Co-Pilot • Each Lean Master candidate is entitled to bring along one assistant (referred to as co-pilot) to the wave. The co-pilot may attend and assist either in a whole wave or part of a wave • If a co-pilot attends only a certain topic in a wave the Lean Master candidate can bring another co-pilot for remaining topics in that Wave • In Summary: A Lean Master can have 1 co-pilot with him (need not be same person) on each Topic of the training • A co-pilot who attends at least one whole topic receives a co-pilot certificate Manufacturing & business solutions towards increased profitability

  29. Executives & Sponsors • Executives and sponsors will be invited to sit in selected sessions throughout the Lean Master training • The topics selected for Executive participation is to: • Expose executives to concepts of Lean & TOC • Understand diagnostic findings of candidates and approve of area of focus for improvement • Show sponsorship in Leading the Change process • Be familiar with the Performance Measurements used by Lean Masters Topics which executives should participate Lean Overview, Theory of Constraints, Performance Metrics, Change Leadership, Value Stream Mapping & Lean Roadmap Manufacturing & business solutions towards increased profitability

  30. The Lean Master Program Structure Lean Master Candidates Attend 5 Waves & Complete 3 Projects Each The client gets 7-10 candidates trained as internal Lean Consultants with all the skills necessary to Diagnose, Strategize, Improve & deploy Lean factory-wide Co-Pilots Attend Specific Topics & Assist in Projects A big group of second level assistants may attend 1, 2 or up to 4 waves to be trained in specific topics of interest or importance in their area. Co-Pilots are similar in level in Lean to the Green Belts of Six Sigma Executives Attend Important Selected Topics Executives such as Plant Manager, Senior Directors, Department Heads etc. will be exposed to important aspects of Lean Concepts and will be able to participate in key diagnostic findings and approve improvement focus for the team Manufacturing & business solutions towards increased profitability

  31. In Conclusion-A Complete Development Program The Lean Master program sets the framework for the development of a complete Lean Academy in an organization The Lean Master Program Structure A Value Stream Map Of Client Site Created at Wave 1 The client’s site VSM shows actual Value Adds & Non Value Adds. Actions and Lean Projects will be focused on tapping opportunities found in this VSM Projects Are Based On Actual Issues In Client’s Shop-Floor All projects will be based on real shop-floor problems. The client will start to reap benefit of the Lean Master program right after Wave 1 Lean Roadmap Is Created In Wave 4 To Guide Lean Proliferation Executives & Candidates together are involved in creating a Future State Value Stream Map and a road map for full Lean deployment. A structure of Lean Organization within the client’s factory could be formed here with the guidance of AMC consultants Manufacturing & business solutions towards increased profitability

  32. BENEFITS

  33. Benefits • Lean Master Program trains a set of internal Lean Consultants with the knowledge st to: • Diagnose Factory problems • Strategically focus Lean Improvements in areas which matter most • Have skills to actually use the Lean Tools to solve problems • Handle Change management Issues • The project completion requirements will give savings & benefits to clients right from wave 1. There have been instances where the client had offset or exceeded cost of training even before the end of the program Manufacturing & business solutions towards increased profitability

  34. Benefits • Typical savings through Lean Master projects in the past include: • Up-to 50% reduction in bottleneck machine setup time • OEE improvement in capital intensive machines by up-to 30% • Reduced excess WIP holding up to 50% resulting in savings up to RM 20,000,000 (one-off saving) • Reduced Cycle Time by up to 30% • Reduced Scrap up to 2% (amounting to about USD120,000/year) • Capital avoidance by up to USD1,200,000 Manufacturing & business solutions towards increased profitability

  35. Credentials “ Lean Manufacturing in general opinion is too BIG and difficult to be achieved. But with AMC as our trainer/consultants Lean has become easily understood by Belton candidates of all levels. Lean has become applicable in Belton” Pongyut, Director of Engineering Belton Industrial, Thailand “….result is...very ordinary people here ( Production Supervisors, Engineers), moving on very ordinary projects ( Poka--yoke, UPH improvement, Kanban system, etc) for some VERY extra-ordinary results. I  am very pleased that so much dollars and cents has been saved with a lot of simple, sensible and stellar projects. Keep up the good work and I am so proud with all of you.” Comment of Managing Director of Finisar to AMC Lean Master Candidates Manufacturing & business solutions towards increased profitability

  36. Credentials “ Lean Manufacturing came at the right time to save millions of dollars for us in capital avoidance…” Michael, Lean/Engineering Manager MSP, Ipoh (NSK Group) “ Lean Manufacturing is an effective tool to reduce wastage, optimize capacities & reduce costs….AMC’s course taught us the effectiveness of various Lean Tools….The course is very interactive and the simulation games are very interesting. The course instructors use their extensive industrial experience to elaborate important points and make participants understand the key points” Roger Goh, Vice President Beyonics Precision, Johore Bahru Manufacturing & business solutions towards increased profitability

  37. Thank You Question Time LEAN MASTERS ARE CHANGE AGENTSWHO INCREASE PROFITABILITY

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