This course covers the essential principles and techniques of Lean Manufacturing and Total Productive Maintenance (TPM). Designed to equip you with practical knowledge, it delves into Lean tools, the steps for implementing SMED (Single-Minute Exchange of Die), JIT (Just in Time), and the fundamental pillars of TPM, ensuring your organization achieves peak efficiency, reduced waste, and continuous improvement. From value stream mapping to Kanban and equipment optimization, this course is perfect for professionals seeking to enhance production processes, minimize downtime, and drive quality improvements in their manufacturing operations.

Section 1: Lean Manufacturing System – Tools and Techniques

This section introduces Lean Manufacturing, focusing on essential tools and their implementation. You will begin with a basic understanding of Lean and its steps for successful implementation. The section covers key Lean tools like SEITON (organization), SEISO (cleaning), SEIKETSU (standardization), and SHITSUKE (discipline), which are integral in creating an efficient and waste-free production environment. The goal is to equip you with the necessary techniques to streamline processes and achieve operational excellence.

Section 2: Lean Manufacturing System – SMED, JIT

Dive deeper into SMED (Single-Minute Exchange of Die) and Just-In-Time (JIT) systems in this section. Learn how SMED reduces setup time to increase production flexibility and how JIT minimizes inventory while improving process flow. You’ll also explore the value stream mapping technique to visualize and improve production processes, with a focus on the Kanban system for efficient production control. The section concludes with the benefits of implementing JIT and how it can lead to significant cost savings and improved productivity.

Section 3: Total Productive Maintenance (TPM)

In this section, you’ll gain a strong understanding of Total Productive Maintenance (TPM) and its application in manufacturing environments. We’ll explore the types of maintenance, including preventive, predictive, and corrective, and how they contribute to the overall efficiency of machinery. The concept of Overall Equipment Efficiency (OEE) is discussed to help track and improve machine performance. Key TPM pillars such as Quality Maintenance and Safety, Health, and Environment will be covered to ensure a holistic approach to equipment care, enhancing both productivity and workplace safety.

Conclusion:

By the end of this course, you will have a deep understanding of Lean Manufacturing systems, including crucial tools like SMED, JIT, and value stream mapping, and their practical application to improve production efficiency. You will also be equipped with the knowledge of Total Productive Maintenance to enhance equipment reliability, reduce downtime, and ensure a safer working environment. Whether you are looking to optimize your manufacturing processes, reduce waste, or ensure maximum productivity, this course will provide the essential skills and knowledge to drive continuous improvement and operational success.

Who this course is for:

• Manufacturing Professionals: Individuals working in manufacturing environments who want to understand and implement Lean Manufacturing techniques, Total Productive Maintenance (TPM), and Just-In-Time (JIT) systems to improve efficiency, reduce waste, and optimize production processes.
• Operations Managers and Supervisors: Professionals who oversee manufacturing operations and are looking to improve productivity, reduce downtime, and enhance the overall efficiency of their teams and processes.
• Quality Assurance and Process Improvement Specialists: Those involved in quality management, process improvement, or continuous improvement initiatives who want to deepen their understanding of Lean tools like SMED, Kanban, and value stream mapping to improve production systems.
• Industrial Engineers: Engineers focusing on improving manufacturing systems and processes, aiming to apply Lean and TPM principles to design and optimize workflows.
• Lean Consultants and Trainers: Those interested in teaching or consulting on Lean methodologies and practices, looking to enhance their knowledge of Lean tools and techniques for various industries.