Lean Manufacturing Courses

Aimed at the permanent maintenance of a flow of tense, adjusted and flexible production.

Our Lean Manufacturing courses will teach attendees how to eliminate waste and prepare annual plans of strategic productivity objectives for their companies.

The ITEMSA Lean Manufacturing courses will train your employees to ensure the creation and permanent maintenance of a flow of tense, adjusted and flexible production in your company’s workshops, tending to the "piece by piece":

  • Eliminating or significantly reducing wastage in labour, materials, machinery and inadequate work methods.
  • Creating and maintaining a clean, organised, safe work environment with greater operational efficiency (5S).
  • Optimising methods and work times, through the application of MTM and/or timing, in a cultural environment of continuous improvement..
  • Performing a total productive maintenance (TPM) of machinery and facilities.
  • Minimising machine preparation and model change times (SMED).

The Lean Manufacturing intervention area includes all the techniques of a Comprehensive Production System, which includes, among other aspects, product quality, work and information flows, materials, machinery and equipment, working methods and the labour force, the workshop chain of command and the constant improvement of the jobs, in order to achieve the best results for the objectives of quality, cost, flexibility and customer satisfaction established in the company.

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Initial situation:
Need to successfully implement the techniques for productivity improvement and the assignation of correct times of execution to improve the processes productivity.

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Concepts, principles and management essential indicators of Lean Manufacturing

How to establish a dashboard with key performance indicators to assess the impact of the actions adopted to correct the deviations in Quality, Cost, Deadline and Safety objectives. The key is to detect the MUDAS (wastes) in present processes and to persist in their elimination.

Duration: 24 Hours

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Necessity for change towards the Lean: the most appropriate planning and management techniques

How to implement the change towards the Lean Manufacturing system through the design of a plan of annual strategic objectives and how to achieve that everybody feels involved in its achievement (commitment and discipline) in their respective area of responsibility by using the KAIZEN techniques and continuously applying the PDCA (Plan-Do-Check-Act) cycle.

Duration: 30 Hours

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Workshops and offices improvement techniques

How to engage workers and workshops and offices middle management with the three basic pillars of Lean Manufacturing:
  • Standardization
  • Workers training for polyvalence
  • Application of the 5S and SMED (Single Minute Exchange of Dies)
Duration: 24 Hours
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Techniques for the optimization of the materials flow and internal stocks in the processes

How to use JIT (Just-In-Time) concepts and techniques to improve the materials flow and reduce stocks by standardizing the number of pieces in each container (Kanban – quantities by reference and type of container), Lay Out improvement techniques, WIP (Work In Process) definition and standardization, etc.Duration: 40 Hours
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Operations standardization and workers training for polyvalence

How to standardize operations and continuously ensure the objectives of Quality, Cost and Deadline, in a safe and ergonomic environment. This standardization is crucial, so that all workers acquire the same theoretical and practical knowledge with minimum differences.This knowledge is the basis for the worker’s development, according to a rigorous and gradually expandable training procedure, in order to enable him or her to perform several jobs with satisfactory quality, productivity and safety levels.Duration: 18 hours
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Problem solving and decision making techniques

How to exactly define a problem by using objective and truthful information, and then solve it through the search and elimination of its causes by applying the QCS (8D) procedure and the basic tools of quality.How to select the most appropriate activities to eliminate the cause for the problems, by using an appropriate decision making procedure.Duration: 12 Hours