Education and Training
Courses 2010
To support Lean and Agile Manufacturing Planning
and Control including capacity and inventory /
stock / work in process (WIP) management, implementation of Just in Time (JIT), Kanban,
Master Production Scheduling (MPS), Rough Cut Capacity Planning (RCCP), Advanced
Planning & Scheduling (APS), Materials Requirements Planning (MRP1)/ Manufacturing
Resources Planning (MRPII), Enterprise Resources Planning (ERP), Shop Floor Control, and
Managing Product & Process
Data.
Our
Training Philosophy and Approach
The following 21 training courses are available. They can be readily tailored to
suit individual requirements for in-house
workshops.
To discuss your
consulting or training needs with one of our independent consultants
or trainers please
Contact Us.
More Best Practice and
Training Links below
Manufacturing Course Summaries
M01 Designing, Implementing
and Operating Kanban Systems (2 days) (Course Schedules),
(Request course
details)
Designed for:
Lean Manufacturing / JIT / Kanban
/ Pull system designers and implementation project teams,
team
leaders / department heads of manufacturing
Course Objectives:
Pull systems offer clear bottom-line benefits if done
properly.
This detailed course will enable you to design, implement
and maintain your own Kanban systems and deliver the bottom line benefits
of:
- Up to 75% less stock, space4
- Fewer rejects (because you find them earlier)
- Up to 80% reduction in lead-times4
- Almost no double handling
- Better housekeeping
- Less cost of control.
Course Highlights & Examples of
course participant's feedback:
This course will show you how to:
- Deal with the prerequisites to the use of Kanban systems
- Select, from the 8 types of Kanban system available, to provide the best fit for
your application
- Design Kanban systems:
- Define process relationships to make Kanban simple to use
- Calculate Kanban quantities
- Position buffers
- Devise simple signalling mechanisms
- Integrate Kanban systems with:
- Implement the system
- Understand the people implications
- Choose your first situation
- Sell the idea to operations staff? (Includes
M22a below)
- Maintain a Kanban system
- Avoid the problems we have encountered in a number of Kanban rescue
projects we have been involved in, where the systems were not delivering
the bottom-line benefits, because they were either ill-conceived,
inappropriate, badly implemented, or badly maintained.
Note 1: A MS Excel template for calculating required Kanban
population sizes is supplied with the course.
Note 2: A copy of our
Kanban & Lean Simulation Game toolkit (see M22a below)
is included with this course.
Note 3: A complete in-house
task force lean manufacturing training programme is available for the reorganisation of
manufacturing under JIT and Lean principles. See
M14 Lean & Agile Manufacturing Detail (Pick & Mix)
(below)
Note 4: Based on our best
project benchmarks
M02 Advanced Scheduling Systems (APS) (1
day) (Course Schedules),
(Request course
details)
Designed for: All levels of production
planning and inventory management personnel
Choosing and getting the best from scheduling systems is
the part of scheduling systems implementation that the software does not help
and the software supplier may not be the appropriate person to ask.
Course Objectives:
This detailed course, which is software
independent, discusses scheduling from first principles up to
advanced techniques and will enable you to select an appropriate scheduling
system then design, implement & operate the system to deliver the bottom line benefits of scheduling
with minimum administration.
Course Highlights & Examples of course participant's
feedback:
This course will show you how to:
- Identify the prerequisites
- Define your approach (define your problem)
- Select an appropriate scheduling system (which of the 11 degrees of
scheduling sophistication you need) and how to justify it?
- Then design, implement & operate the system
- Apply the underpinning principles of scheduling
- Design the model
- Create & maintain the data
- Implement the system Operate and maintain the system
- to deliver the bottom line benefits of scheduling with
minimum cost & administration
M03 Bill of Materials and Routings
Design & Management (1 day) (Course Schedules),
(Request course
details)
Designed for: All levels of product design, inventory management, production
planning personnel and teams responsible
for ERP / MRP implementation
Course Objectives:
Bill of Materials (parts lists / ingredients lists) & Routings (methods of
manufacture) are at the heart of a manufacturing process. They not only define
the product & process, they also provide a structure to manage ALL of your
business processes, from purchasing to after-sales. Correct design and timely,
accurate maintenance is essential and
if done badly, a significant source of problems and inefficiency.
Designed in conjunction with
D02
Specification Change Management: (Managing Product, Computer Programme,
Documentation, or Process changes), this detailed course will enable
you to
design and implement your own simple Bill of Materials and Routings and
their maintenance processes to
satisfy the potentially conflicting needs of design, materials
planning, capacity planning, work-in-process tracking, product
costing, inventory accounting, service and repair and last but not least,
quality control. It also defines the key requirements of change control.
Course Highlights & Examples of
course participant's feedback:
This course will show you how to:
- Provide the necessary degree of control whilst reducing
administration across the business by:
- Designing your Bill of Material for effective & efficient control
- Defining the relationship between Bills of
Materials and Routings & designing your Routings to enable efficient &
effective scheduling
- Use Product and Process Data in planning and control systems such as MRP
- Manage product and process changes to provide rapid implementation but
with safeguards to minimise disruption and obsolescence
- Design a version control system for changes in products and processes
which will facilitate implementation of change
- Deal with the impact of version control on lot traceability and enable a
minimal product recall
- Facilitate accurate business planning & control
- Avoid some of the expensive reimplementation projects we have
been involved in to avoid severe operational difficulties
- Produce a task list for implementation
M04 Participative Master Production
Scheduling (P MPS) (1
day) (Course Schedules),
(Request course
details)
Designed for: All stakeholders in the planning process including sales
managers, operations managers / team leaders, supplies / purchasing managers, and planners
Course Objectives:
How do you satisfy customers AND utilise resources
effectively AND meet the business plan?
Two of the key requirements of out of the 15 we explain in
this course are:
-
To create a participative, operational,
planning process, involving stakeholders, to agree
a single plan
-
And then measure performance based on achieving it
This detailed course, designed in conjunction with M05
Simple Capacity Planning & Control (below), is focused on the
attributes of a best practice operations planning process in order to:
- Identify weaknesses in your current operations planning process or
design your own Participative MPS process by using our unique 15 point
self-appraisal
- Provide an integrated Capacity & Materials planning process to balance load and capacity
(and reduce inventory)
- Produce a task list for implementation
Course Highlights & Examples of
course participant's feedback:
This course will help you to:
- Understand the relationship between Development Sales and Operations Management (DS&OM), Master Production
Scheduling and Shop Scheduling
- Design and create a production planning process that delivers products
on time and at short lead-time but also manages resources effectively
- Manage seasonal or variable demand and sales promotions
- Size batches correctly
- Avoid complex scheduling systems
- Manage the introduction of new products into production
- Produce an action plan for implementation
Note 1: This course is also available as an in-house workshop. When run with all the
stakeholders in the room it produces an outline design and implementation task
list.
Note 2: This course assumes a passive role of the management of
the sales & development processes. Our course SSC08 Participative
Development, Sales &
Operations Management in addition assumes an integrated Sales Management, &
Product Development
Process (e.g. Sales Planning) driven by a Participative, Development, Sales & Operations
Management process.
M05 Simple Capacity Planning & Control (1 day) (Course Schedules),
(Request course
details)
Designed for: Master Production Schedulers, planners and
operations team leaders
Course Objectives:
The simple objective at
level 2 of the capacity management
process is to create a "do-able" plan (& then do it "On-Time In-Full")!
Firmly following lean principles,
this detailed course, designed in conjunction with
"M04 Participative Master Production Scheduling" (above) and
"M11 Simple Ways to Maximise Output & Workflow"
(below) will enable you to create; implement; and operate your own simple,
low cost, capacity management process incorporating simple tools to:
- Give customers the earliest delivery and accurate delivery promises
- Get the most from your resources
- Avoid feast & famine in operations
- Identify inconsistent output
Course Highlights & Examples of
course participant's feedback:
This course will help you to:
- Plan and control capacity effectively
- Understand how load and capacity interact
- Understand the weaknesses in your current capacity management
-
Avoid scheduling complexity
- Balance process capacity
- Quickly check if you have the capacity available to deliver
when required and make accurate promises to customers. ("Available
To Promise")
- Create simple capacity models and use them effectively to plan and
control operational capacity, featuring detailed explanations of the
design & use of:
- "Rough Cut Capacity Planning (RCCP)"
- "Takt time"
- Use other simple methods of Capacity Control
- Define procedures for maintaining the process
- Implement the process
- And last but not least:
Get more output
for free!
Note: Includes our MS Excel
Rough Cut Capacity Planning model template to get you started quickly.
M06 Stock & Work in Process (WIP)
Tracking (1 day) (Course Schedules),
(Request course
details)
Designed for: All levels of inventory and operations personnel, expeditors
and teams responsible for ERP / MRP
implementation. In short, everyone who moves work around.
Course Objectives:
Knowing what you have, how many, & it's current status,
facilitated by controlling work in process levels, are not only key requirements
of accurate production planning, but also of production control, with its goals
to meet the plan and
maximise productivity, whilst minimising lead-time and stock levels.
This detailed course, (which is independent of
software), will enable you to support accurate stores and
work in process tracking processes by outlining modern, commonly used, control
methods and by emphasising the importance of accurate recording in production
planning & control in 4 modules:
- Stores Control
- WIP Control & Work Order Management
- Controlling WIP Levels
- Stock & WIP Accuracy
Course Highlights & Examples of
course participant's feedback:
This course will show you how to:
- Diagnose problems in your current system or design a system that keeps
track of your stock and WIP accurately
- Maintain work in process accurately by:
- Processing work orders accurately following the key stages of the
work order life cycle
- Managing line-side / point of use stock correctly
- Manage work in process levels properly
- Identify & install the disciplines necessary to maintain accurate stock
and WIP records
- For your situation, create a development task list to manage inventory well
Note 1: A companion course for pure warehouse operations is
SSC06 Warehouse Operations
Management
Note 2:
M17 Stock & WIP Tracking for Beginners (below) provides a short
introduction to this topic as part of an MRP "educating the critical mass"
initiative (available only as an in-house
workshop).
Below are three MRP Training Courses,
Beginner;
MRP1; MRP2:
M07 MRP for beginners
(½ day) (Course Schedules),
(Request course
details)
Designed as: An introduction to MRP systems and as a means of educating
everyone connected with an MRP system
Course Objectives:
In order to deliver the bottom
line benefits everyone who comes into contact
with an MRP system needs to have a basic understanding of how it works; what
data it uses; and the importance of data accuracy. As one Operations Director said to us,
"they need to be reminded every 2 to 3 years too!"
This detailed course, (which is independent of
software) provides a short introduction to this topic, as part of an MRP
"educating the critical mass" initiative, by providing an understanding of:
- How MRP logic works
- The business processes & data required to drive it
- The importance of procedures and disciplines to maintain data accuracy
Course Highlights & Examples of course participant's feedback:
This course will help you to:
- Understand the types of MRP systems available and the difference between MRP1 and
MRP2
- Understand the essential requirements of an effective MRP system
- Decide when these systems are appropriate
- Avoid common problems we have encountered in implementing & rescuing
these systems since 1981 & the severe impact of these problems
- Discover how MRP does the calculations
- Understand what data is used and how is it
maintained
- Understand how your actions impact
the effective working of an MRP1 system
- Contribute to solving the problems
Note 1: An MRP1 simulation model is used to illustrate the
effects of data in the system.
Note 2: This course forms the first half day of
M08 below.
M08 Material Requirements Planning
(MRP1) (1 day) (Course Schedules),
(Request course
details)
Designed for: All levels of planning, inventory management and operations
staff and especially for teams responsible
for ERP / MRP implementation, or trying to improve MRP performance and
particularly valuable to people new to MRP.
Course Objectives:
In principle an MRP1 system should be a
Just In Time system.
There are 3 exceptions (agricultural crops, products /
processes requiring maturation, and strategic spares, the effect of which can be
ring-fenced), but otherwise you should be able to achieve:
an overall stock turn roughly equal to 1-2 times the
process lead-time of a typical job that you are expediting through the
process without queuing (E.g. If your overall manufacturing lead-time
without queuing is 2
weeks, you should have about 2-4 weeks' worth of total inventory);
with excellent customer service (>98% of customer orders / schedule call offs, On-Time-In-Full). (See
Achievable Benchmarks)
This detailed course, designed in conjunction with M09
MRP2 (below), which is
independent of software, provides a detailed understanding
of MRP1 design, implementation and operation considerations. If your current
MRP system is not achieving our benchmarks above, or you are about to implement
your first MRP system, or you are new to MRP, this course is for you!
Course Highlights & Examples of course participant's feedback:
In addition to the content of M07 MRP for Beginners
(above) which forms the first half day of this course, this course will
help you to:
- Understand why MRP systems often fail
- Design an MRP 1 system
- Implement an MRP 1 system
- Maintain and improve an MRP 1 system:
- Measure MRP performance
- Deal with exception messages effectively
- Understand the full work order life cycle
- Build a control system to drive MRP performance and delivery to plan
- Actually deliver the bottom line benefits promised by the software vendor
M09 Manufacturing Resources Planning (MRP2)
(1 day) (Course Schedules),
(Request course
details)
Designed for: All levels of planning, inventory management and operations
staff and especially for teams responsible
for ERP / MRP implementation, or trying to improve MRP performance and
particularly valuable to people new to MRP.
Course Objectives:
In addition to MRP1, MRP2 introduces a new level of potential
benefits and sophistication into the scheduling of production. Whilst it adds
more discipline to the management of work-in-process and integrates finance &
purchasing, it also creates another layer of data to be managed. As a
consequence good MRP2 implementations where plans
are actually met (compliant) are still hard to find.
Designed in conjunction with M08 MRP1 (above)
which is a prerequisite, this detailed course, (which is independent of software), provides a detailed
understanding of MRP2 design, implementation and operation considerations.
Course Highlights & Examples of course participant's feedback:
This course will help you to:
- Understand the difference that scheduling makes to delivery
performance and productivity
- Overcome common Capacity Requirements Planning / scheduling problems
- Design an MRP 2 system
- Implement an MRP 2 system
- Maintain and improve an MRP 2 system
- Manage the "work-to" list
- Become a "high compliance" manufacturer:
- Produce "do-able" plans that are met
- Maximise productivity
M10 Simple Stock Control (1
day) (Course Schedules),
(Request course
details)
Designed for: All levels of inventory management and operations staff and especially for teams responsible
for implementation of simple or lean and visual materials control systems
Course Objectives:
Simple, inexpensive, but very effective, stock control
systems for repetitive items and consumables are an integral part and key
requirements of a "Lean" / "Just In Time" implementation. But a common mistake
in the use of these methods is that they are perceived as "fit-and-forget". Like
all other control systems they require: appropriate selection; proper design; good
implementation; and ongoing, but low cost,
maintenance!
This
detailed course, designed in conjunction with M11 Simple
Ways To Maximize Output & Workflow (below), firmly based on lean
principles & which is independent of software,
provides a detailed understanding of selection criteria; design, implementation
and operation of simple, low cost, stock control
and point of use / line-side stock replenishment systems.
Course Highlights & Examples of course participant's feedback:
This course will help you to:
-
Select an appropriate, simple,
control system for your situation
-
Avoid shortages / excess stock by
regularly calculating safety stock and re-order points correctly
using our simple MS Excel spreadsheet template Note 1
-
Manage material movement with
low administration and avoid double handling
-
Design, Implement and Maintain:
-
Replacement systems
-
Two Bin Systems
-
Three Bin Systems
-
Vendor Managed Inventory
(VMI) processes
-
Deliver to point-of-use
systems
-
Simple visual controls
from our 30 examples
-
Reduce your administration
costs, improve workflow and "right-size" stock levels
-
Produce a task list for
implementation
Note 1: Includes a simplified
version of our
Excel spreadsheet template for you to take away (This course and this
template contains very basic content from
SSC03 Advanced Forecasting & Inventory
Modelling using spreadsheets)
Note 2: Includes a brief
introduction to Kanban systems for which a comprehensive and detailed course on
Kanban / Just-In-Time is contained in
M01 Designing, Implementing & Operating Kanban Systems (above)
M11 Simple Ways To Maximize
Output & Workflow (1 day) (Course Schedules),
(Request course
details)
Designed for: Operations team leaders, operations staff and teams responsible for improving operations
performance
& useful for operations planning personnel.
Course Objectives:
More People, More Stock, More Equipment, More Control
Systems, More Computers, do not necessarily equal more
output, and hardly ever make work flow.
They do, however, increase cost!
This detailed course, designed in conjunction with M10
Simple Stock Control
(above), firmly follows lean principles, to
provide a detailed understanding of the design, implementation
and operation considerations of simple, easily learned, tools, techniques and
procedures to maximise output and workflow.
Course Highlights & Examples of course participant's feedback:
This course will help you to:
M13
Manufacturing Accounting for Beginners (1 day) (Course Schedules),
(Request course
details)
Designed specifically for: Junior, unqualified, finance, support staff working
in a manufacturing environment, or others wishing to understand
the principles and practice underpinning their finance systems
Course Objectives:
Junior, unqualified, staff in the finance department can
make a significant contribution to profitability by recognising when things are
beginning to go off the rails,
not when the wheels are already off, (when the
problem is bought to the attention of senior management). All you have to do is
show them what to look for, instead of expecting them to go through the tasks by
rote.
This detailed course provides in laymen's language the underlying
principles, practice and limitations of key aspects of financial control in
a manufacturing business namely:
- The planning & control of expenditure: The budgeting process and
budgetary control
- What products cost: Product costing / standard costs
- Overheads and how they are accounted for
- Stock value & variance accounting
Course Highlights & Examples of course participant's feedback:
Topics covered include:
- Understanding budgets & management accounts
- The purpose of costing; Cost objects; Cost granularity (level of
detail); Accuracy / direct / indirect costs; Identifying fixed and
variable costs; Which cost to worry about (Pareto analysis)
- Product costing
- Separate fixed & variable costs; Standard Costs & Actual costs;
Manufacturing strategy and the effect on accounting; Cost Elements:
Materials; Materials Overheads; Sub contracting; Labour; Fixed Overhead;
Variable overhead
- The way ERP systems calculate product costs: Cost roll up; Std. vs.
actual; The implications for estimating new work
- Management accounts
- The Role; Management Accounts Structures; Adding Value; Actual Costs &
Variances; Absorbing Overheads; Variance Analysis (Explaining the reasons);
Budgetary control & Variance
- Financial accounts
- Accounting treatment of variance
- Stock gains & Losses
Note:
OM04 Finance for Team Leaders provides alternative content from a team
leader's viewpoint
M14 Lean & Agile
Manufacturing Detail (Pick & Mix) (1-28 days) (Course Schedules),
(Request course
details)
Create your own in-house workshops in your drive to improve your business from our range of lean & agile
manufacturing training courses including:
Introduction / executive overviews:
M15 Agile Manufacturing Overview
M21 Lean Manufacturing
M19 How to become a “world class” manufacturer
Details:
M01 Designing Implementing & Operating Kanban systems
M05 Simple Capacity Planning & Control
M10 Simple stock control
M11 Simple ways to maximise output & workflow
M22a Kanban & Lean Enterprise Simulation Game
SSC04 Production
Planning & Control Back To Basics
S13 Culture Development Methods
Continuous improvement:
C01 Focused Improvement Systems
C02 Setting Key Performance Indicators
C03 Measures of Performance Detail
C04 Continuous Improvement Basic Tools & Techniques
Forming cells / teams:
S02 Business Process Reengineering
Operations Management:
OM01 Organising & engaging the team
OM03 Organising & managing the workplace
Supply Chain:
SSC01
Tools Techniques & Modern Trends in Supply Chain
Management
SSC07 Strategic Supply Chain Management
Product Management:
D01 New Product Introduction
D03 Six steps to near perfect quality
M15 Agile Manufacturing Overview
(1 day) (Course Schedules),
(Request course
details)
Designed as: An executive overview course
Course Objectives:
Leanness without agility simply leads to shortages! To be
lean you have to be agile and to be agile you need to be lean. Lean initiatives target
waste, whilst agility targets responsiveness!
Designed to accompany your strive towards growth and profitability & aimed at all aspects of manufacturing businesses, (not specifically at
operations), this course is intended to
provide a road map to an Agile business.
Course Highlights & Examples of course participant's feedback:
This course will help you to:
- Understand the key features of an Agile Business
- Create and prioritise a task list to develop an Agile business
- Learn a number of important techniques used to create an Agile Business
- Make your products and services easy and mistake-proof for you to provide & for
your customers to use
- Provide value for money
- Make your products more competitive
- Get products to market quicker and reduce the risk of product recall
- Create a skilled flexible and mobile workforce
- Make decision-making easy and rapid
- Make things easier to do (Internal Processes, Procedures, Logistics, and Communications)
- Make resources quick change; one touch processes (Facilities / Operations Processes / Equipment /
Technology)
- Reduce supply chain risk whilst increasing resilience and reducing
lead-time
- Gain the extra benefits of Agile over Lean
Note 1: This course includes a copy of our unique
118 point agility self diagnosis, to
enable you to create your own Agile implementation task list.
Note 2: Also see
M14 above
M17 Stock & WIP Tracking for
Beginners (½ day) (Course Schedules),
(Request course
details)
Designed for: The novice or newcomer to managing inventory,
warehouse and shop floor materials control personnel, and as a critical mass
awareness workshop in MRP implementations or rescue projects
Course Objectives:
In the haste to ship product, the equally important task of
maintaining the integrity of stock and work-in-process records sometimes comes a
poor second. But this week's stock discrepancy is next week's lost output!
Designed as an introduction to the topic and to sell the message of stock and
work-in-process accuracy, this course identifies key sources of error and faulty
processing, and motivates individuals to improve recording integrity.
Course Highlights & Examples of
course participant's feedback:
This course will help you to:
- Understand why stock management is important
- Overcome the problems and provide solutions
- Understand why accurate stock and work in process recording is essential
- Understand the key features of warehouse management
- Understand the criteria for setting and maintaining stock levels
- Understand the key stages of the work order life cycle
- Understand the key requirements point-of-use / line side / 2 bin
maintained stock
- Understand the disciplines required and the repercussions of not having
them
- Implement techniques which can be used to improve inventory accuracy
- Create an action plan to improve the process
Note 1: A companion course for pure warehouse operations is
SSC06 Warehouse Operations
Management
Note 2: A one day detailed
& more advanced version of this course is available in
M06 Stock
& WIP Management (page one), which should be viewed as a follow-on course
for novices.
M19 How to Become a World Class
Manufacturer (1 day) (Course Schedules),
(Request course
details)
Designed for: All levels of management,
team leaders and especially useful as a workshop for teams responsible for World Class
implementation programmes
Course Objectives:
Leadership requires a vision. But a World Class vision without a plan
will remain a dream!
This course draws on strategic content from a number of our
courses and our experience of implementing world class development programs in a
number of industries to show you:
- A vision of a world class organisation
- A benchmark of your situation against that model
- A route map to achieve it
Course Highlights & Examples of
course participant's feedback:
This overview course, aims to provide
an understanding of what world class is and a route map to
achieve it.
This course will help you to:
- Identify the key differentiating characteristics of leading manufacturing
companies:
- Benchmark your business against leading best practice
- Understand the five types of change and when to use them
- Develop a product and process development process
Note: Includes a number of our diagnostic health checks
M21 Lean Manufacturing Detail (2 Days) (Course Schedules),
(Request course
details)
Designed for: All of the management team
(not just operations) and especially
for teams responsible for Lean Manufacturing implementation and personnel
expected to contribute to the implementation
Course Objectives:
"Lean Manufacturing" has been around for over 30 years now
but how many manufacturing businesses do you know that are truly lean based on
our definition?
This detailed course aims to
provide practical instruction in designing and implementing lean
practices and processes.
Course Highlights & Examples of
course participant's feedback:
This course will help you to:
- Day1
- Establish durable improvement, focused on the six performance drivers (From
C01 Focused Improvement Systems)
- Understand the essentials and benefits of Lean Manufacturing and
the common causes of only achieving temporary effects
- Understand what Just In Time (JIT) really means and the common causes
of failure
- Apply the 15 principles of Lean Materials Planning
- Sell the message (From
M01 Designing Implementing & Operating Kanban systems
/
M22a immediately below)
- Day 2 (Content the same as
OM03 Organising & managing the workplace)
- Remove waste & streamline the flow of work
- Remove complexity & organise your process
- Maintain good housekeeping: (The Six Steps to a Perfect Working Environment)
- Apply simple, inexpensive, Visual Controls (from our list
of 30 ways to Visually manage your workplace &
work)
Note 1: A one day executive overview of lean
manufacturing is available as an in-house workshop.
Note 2: Also see
M14 above
M22a Kanban and Lean Enterprise
Simulation Game (1 Day)
(Course
Schedules), (Request course details)
Designed for: Kanban & Lean
implementation teams and specifically as a "train the trainer" workshop for
onwards delivery to explain to operations personnel why Kanban / Lean is
a better way
Course Objectives:
Kanban and Lean Manufacturing require the active
participation of all employees. One of the key causes of failure we have
observed (and rescue situations we have been involved in) is a breakdown in the
simple disciplines required, caused either by a lack of understanding or lack of
involvement of operations personnel.
One step beyond the stickle-brick and beer games, this
unique toolkit allows you to
create a more persuasive Kanban and Lean Enterprise Simulation Game by
simulating your own products and processes.
Course Highlights & Examples of
course participant's feedback:
This
one-day course, which includes a free copy of the Kanban &
Lean Simulation Toolkit (described below) will enable
you to discover for yourself:
- How Kanban / Lean systems work
- How our game can be adapted to provide your people with relevant and
powerful messages on the benefits (to
everyone) of:
- Kanban
- Lean manufacturing
- Cellular Manufacturing
- Team working
- Continuous improvement
- To make this easier we already have adaptations of the game to
suit a number of environments including:
- Machining; Mixing; Assembly (low volume & high volume); Waste disposal;
Printing; Paper; Composites; FMCG's; Food & drink
The Simulation Game Tool Kit
made up of five parts:
- A Project Plan
- A Product and Process Design Guide (to enable you to adapt our
sample product and process to mimic your environment)
- Instructions for Trainers (running the game)
- A starter pack set of PowerPoint slides, which you can adapt to suit your
training message
- Instructions of how to adapt the game to reinforce
the team working,
cellular manufacturing,
continuous improvement,
and lean enterprise,
messages.
M23 Capacity Management
Foundation Course
(2 Days) (Course Schedules),
(Request course
details)
Designed for: Operations planning
personnel, team leaders and supervisors
Course Objectives:
Having too many, or too few, of the required resources at the
right time is
always very painful and can be fatal! Getting the most from them is not trivial!
This detailed, introductory course, will enable you
to design and implement your own capacity management processes and
evaluate the applicability of different capacity planning and control
options in order to improve the processes which manage capacity and
drive capacity improvement in order to:
- Tell you how much capacity you need and when
- Create "do-able" plans that tell you how full you are
- Deliver your capacity's real potential & reveal hidden capacity
- Reduce lead-time
- And last but not least: Get more output
for free!
Course Highlights & Examples of
course participant's feedback:
This course will help you to:
- Day 1: Medium to Long Term: Matching Capacity to Your Sales Potential
& Business Plan
- Module 1: Introduction: Performance Drivers & Common Problems
- Module 2: Strategic Capacity Planning / Business Planning
- Module 3: Development, Sales & Operations Management (DS&OM) / Master
Production Scheduling
- Module 4: Simple Capacity Modelling / Rough Cut Capacity Planning (RCCP)
- Day 2: Short Term: Coordinating Work & Maximising Throughput
- Module 5: Maximising Workflow & Simplifying Scheduling
- Module 6: Workflow Control
- Module 7: Process Management (Creating & Sustaining The Best Method /
Quick Change)
- Module 8: Implementation & Driving Improvement
- Action Planning
Note 1: M24 Materials Management (below)
provides complementary content for planning personnel and
together they form a
solid foundation course for new planners
Note 2: This course includes overview and introductory content from courses
M02,
M04, M05,
M11 above, &
S02 Business Process
Reengineering, S04
Strategic Capacity Management; S05
World Class Change Management;
SSC08
Participative Development, Sales &
Operations Management;
OM02 Managing &
Improving Individual Skills & Overall Skills Levels
M24
Materials Management & Stock Control Foundation Course (3 days) (Course Schedules),
(Request course
details)
Designed for: Operations planning personnel, team leaders and supervisors,
and especially for newcomers to this subject
Course Objectives:
The now, well accepted, Just-In-Time philosophy is still a
fairly rare, practical, day-to-day reality.
This detailed,
introductory, course will
enable you to design, implement and maintain good materials management practice to
consistently
deliver excellent customer service with minimum effort and inventory. It
includes overviews of current best practice thinking in materials planning and
control systems and provides introductions to the most popular and
effective
ones.
It will help you to:
-
Remove shortages, and contain expediting activity
-
Improve customer service
-
Avoid excess stock, obsolescence and shelf life
problems
-
Actually deliver the
Just-In-Time theory
Course Highlights & Examples of
course participant's feedback:
It covers the following topics:
- Day 1: The Basics
- Module 1: Manufacturing
Strategy & Inventory Strategy
- Module 2: Planning &
Control Processes
- Module 3: Variation,
Stock Levels, & The Classic Max-Min Reorder Point Methods Plus
Refinements
- Module 4: Just in Time (JIT)
& Visual Control Systems
- Day 2: Introduction to the 28
Types of Planning & Control (Push / Pull) Systems & Choosing One
- Module 5: MRP1 / MRP2 /
Advanced Planning (APS)
- Module 6: Another 4
Push Systems
- Module 7: Overview of
7 popular Pull Systems including Kanban & Top up point of use
- Module 8: Overview Of 14
Complementary Planning & Control Methods & Modern Trends
- Day 3: Materials Control; New
Trends & Improving your Process
- Module 9: Designing a
Materials Control Process
- Module 10: Workflow
operational processes
- Module 11: Lean & Agile
Manufacturing
- Module 12: Driving Materials
Management Performance
And last but not least: How do you increase on-time
delivery, remove the shortage list, and reduce inventory simultaneously!
Note 1: M23 Capacity Management (above)
provides complementary content for planning personnel and
together they form a
solid foundation course for new planners
Note 2: This course includes overview and introductory content from
courses M01, M06,
M08, M09,
M10, M11,
M15, M21, (All
above). It also includes content from our Supply Chain Management range of
courses including: SSC02
Materials Control Process Selection (which is in fact Day 2 of this course), and
SSC04 Production Planning &
Control: Back to Basics and
SSC06 Warehouse Operations
Management
_______________________________________________________________
A number of our other courses are
also relevant to manufacturing companies.
_______________________________________________________________
To discuss your
consulting or training needs with one of our independent consultants
or trainers please
Contact Us.
Home Page
Ó SM Thacker & Associates
(Consultancy and Training Specialists) Original Jan 2000. Version 16 March 2010
