Training Course Program
World-Class Manufacturing - 4-day course
...in a rapidly changing world, featuring vanishing borders and hot, global competition, all manufacturing concerns, including SMEs, must aim at new performance targets in line with "the best in the class-room"...
course contents and main topics
Industrial Performance: definition and measuring methods - self-assessment methods. Approaches to Performance Improvement. World-Class Performance in the Manufacturing Industry: World Class Manufacturing (WCM) - what it is, why it is so important.
Value Adding Management in the Manufacturing Industry: the pilot light and driving philosophy for the new millennium. Focusing on processes to maximise value and eliminate waste. (more »). Today's relationship between value, productivity, and quality. How to "re-engineer" an enterprise for generating high levels of value.
WCM is "world-class" approach to Market and "world-class" relationship with Clients. Orientation to Client id the key: is your enterprise a client-driven organisation ? (more »)
WCM is development of "world-class" products. Is your product what your customers want, need or expect ? How to design, improve, modify and industrialise fast your products for high customers' satisfaction (more »). The concept of "total product".
WCM is "world-class" Operations and Manufacturing Methods. The "state of the art disciplines for manufacturing enterprises: which ones are available, how to deploy them effectively (--> read more about).
Productive Systems - The "batch" and "line" types of Operations - The "push" and "pull" productive methods (more ») - The kanban approach to pull production (more »).
Productive Process Time and Cost Analysis : identifying value-adding and non-value-adding activities (more ») - Case study: "spot the waste !"
The target : Flow Production, or production with no waste (more »).
The relationship between JIT-Just in Time, LM-Lean Manufacturing and Flow Production (more »)
The small-lot production systems: the smaller the lot, the less the waste ! - Simulation: One-Piece Flow - Case study: One-Piece Flow vs. Batch Production
Systematic Elimination of Waste in the manufacturing industry - What is waste : classification of waste (more ») - The SOCO (5S) approach as a starting point for fighting waste (more ») - Halting waste proliferation - Reducing waste - Eliminating waste (more »).
Flow Production in three different situations: labour-intensive - machine-intensive - combination. Case studies.
The stock issue: why does stock pile up and (sometimes) flood the factory ?
What are the necessary requirements to implement Flow Production - Flow Production golden rules (more »). How to reduce drastically all lead times through Flow Production: produce today what your customers ordered yesterday
Is Flow Production suited to you ? The Product-Quantity Analysis - Process Mapping - Process-Razing studies (more »).
Cell Production and Group Technology - Design of manufacturing cells : principles and techniques. When to consider One-Piece production and Cell Manufacturing. How to improve productivity by an average of 35%, by eliminating the bulk of the waste. Continuous Flow Manufacturing (more »).
The need for Quick Change-Over (more »). Why the traditional "Economic Order Lot" principle is today obsolete.
Movie-time: the negative effects of long change-over operations. The "stock" issue. Detrimental effects on people morale. The final result: brain laziness.
Simulation: why traditional change-over time is too long.
Foundations of Achieving Quick Change-Over (AQCO): Team improvement to set-up activities. (more »)
Techniques, hints and tips for Quick Change-Over: Parallel operations - "Bolts and nuts are our enemies" - Functional clamping - Eliminating all residual waste - Benefits of video recording.
Planning for AQCO: this is a project and should be handled as such.
Total Productive Maintenance in the manufacturing industry (more »). Industrial competitiveness today is based on the motto: "Methods first, then Technology". What are the modern principles of Plant, Equipment and Machinery Management. How to prevent major technological mistakes (the "super-star-galactica" cul-de-sac....). What is the ideal Plant layout for real Flow Production and healthy Lean Manufacturing (more »). How to deploy the Systematic Elimination of Waste discipline in medium/heavy mechanised/automated operations (more »). How to harmonise People and Machines in a productive system geared to produce high levels of added-value
What are the main differences between "traditional" TPM and today's TPM (more »).
Today's TPM goals: maximisation of Equipment Effectiveness and added-value - total elimination of waste related to Equipment - high involvement of people selecting designing, operating and maintaining Equipment - "life-cycle" management of Equipment - optimal management of the Industrial Safety and Environment Protection parameters.
How to calculate Overall Equipment Effectiveness (OEE)and associated added-value. How to identify the 6 Big Losses associated with Plant and Equipment. Movie time: how to identify waste of manpower next to Machines and Equipment.
Classification of Losses related to Equipment. How to identify and distinguish between chronic Losses and sporadic Losses. Why certain Losses go undetected, unmeasured, unattended, overlooked: how to instil a new mentality and industrial culture in personnel at all levels. Presentation and in-depth analysis of the main methods and techniques used today for Losses elimination or drastic reduction.
Fighting Plant breakdowns: today's approach is "no machine should break down". How operators can contribute to the target. The TPM approach to zero-breakdowns.
Fighting start-up Losses. Fighting Machines idling and minor stoppages. Fighting poor productivity due to reduced machine speed/capacity. Eliminating poor quality of output product: how to achieve the zero-defects target through Poka-Yoke methods (more »).
Deep involvement and accountability of operators is the main TPM secret: what is Autonomous Maintenance, the "heart" of TPM. Basic principles of Autonomous Maintenance. Education and Training for TPM - TPM for Production Personnel and Workshop Leaders - TPM for Technical/Engineering Departments: a new approach to Plant selection and design.
The new role of the Maintenance Department. How to increase co-operation and introduce integration between Production and Maintenance personnel. How to restructure an enterprise to modern concepts of multi-skill and multi-function personnel. How to reduce significantly all manpower-related waste.
Preventive Maintenance today: Standardisation - Planning - Recording. Maintenance Economics: how to reduce drastically the overall Maintenance expenditure.
How to plan, introduce and launch a TPM project. Movie time: how to increase OEE from 30% to over 90% in 6 months.
How to measure TPM Effectiveness. How to monitor progresses through a radar-chart
...eventually, the dust settled. What is TQM today, what is different from 10 and 15 years ago. Today's core principles of Total Quality Management (more »).
The relationship between Quality Assurance and Total Quality Management. Is the ISO Quality Assurance system really beneficial? When should an enterprise go "top-down" ISO style, and when should it go "bottom-up", kaizen style? Can the 2 approaches be combined? How to harmonise a Quality Assurance System to ISO standards with a TQM System targeting at eliminating all defects. Lean Disciplines: the 6 Sigma Methodology for drastic reduction of process' variability - overview (more »).
Quality Control and Statistical Process Control: are they dead or alive ? In which cases do we still need these disciplines ?
The 5 possible levels of achievement with regard to quality: today we can only target at level 5, or zero defects. How to progress to a "zero-defects" status through Poka-Yoke based methods (more »). Movie time: zero-defects in the automotive industry.
Why quality and productivity are the two sides of the same medal, and should improve simultaneously. Continuous, systematic improvement in Performance: the western kaizen approach, or improvement through people brain-power (more »). Basic tools and techniques for continuous improvement: from traditional Problem Solving to the "New Tools" (more »). Workshop: team-work for zero-defects and better productivity.
The cultural aspects of Quality, and the relationship between Total Quality Management, Value Adding Management (more ») and Lean Thinking (more »).
How to deploy LM techniques in the manufacturing industry - starting from the top or from the bottom? Can Flow Production be extended factory-wide? The mixed "push/pull" compromise. Where and how to position the "coupling" between the "push/batch" and the "pull/flow" systems. Basic Lean and Continuous Flow principles for the Continuous Process manufacturing industry and the highly mechanised/automated factory.
Value Stream Management: a global approach to Lean. The Value Stream Mapping technique: a practical deployment of all Lean Disciplines in an integrated fashion (more »). The VSM "storyboard": a common, practical tool understandable both to Top Management and to Shop-floor people. The "Milestone Charter" and the Kaizen approach to the implementation of Lean Improvement projects.
New relationship with suppliers for Lean Manufacturing. Suppliers classification, rating and grading. Understanding the "Value-Chain" principle in manufacturing and the strategic role of suppliers and sub-contractors. Lean approaches to Supply Chain management. Is "co-makership" suited to you?
The development of Organisational Strategies in industrial history. Possible Organisational Strategies for the years 2000. What is the relationship between enterprises' Organisational Structure and their Human Resources Management strategy (more »). Workshop : Scanning an Organisational Structure and defining the most appropriate HR Management strategy. Harmonising HR Management strategy with enterprise's culture, management style, approach to clients, approach to suppliers, and method of Operations.
TEI - Total Employee Involvement is the "state-of-the-art" discipline for people management in a world-class environment. What are the core principles of TEI (more »). Is TEI suited to all enterprises ?
The main parameters associated with people performance: Quality - Productivity - Responsibility and Accountability - Creativity - Challenge. Why people "don't perform" - why all traditional management and motivational techniques somehow fail.... Why communication is so difficult - why there is a communication problem. Are traditional Leadership and Management methods obsolete ? From the "suggestion box" scheme to total participation. How to generate interest and involvement in people: what is the secret, missing ingredient ?
Movie time: people at work in "traditional Operations" - why frustration and de-motivation are so high. The key is orientation to value. How to transmit basic concepts of Value Adding Management to people (more »). How to insert people in value-generating processes (more »). How to obtain high levels of involvement, commitment, responsibility, accountability, adaptability, flexibility, care, and dedication to work from personnel at all levels. How to evolve from "job description" to "process description". The multi-skill, multi-function factors. Empowerment : the solution ? From traditional Management to coaching: what are the prerequisites.
Today's industry needs teams and team-work. Several types of Organisational Groups : Teams, Project Teams, Improvement Teams, Inter-functional Teams, Re-Engineering Teams. Basic rules and principles for efficient and effective team-work. Workshop: maximising Teams' effectiveness. What is the relationship between TEI and team-work. Why and how the one may benefit the other.
How to give back pride to people and dignity to their work: the Figaro model for Total Employee Involvement (more »).
In advanced world-class enterprises the TEI model is no longer sufficient. What is required is a more "entrepreneurial" style of performance. The ice-cream vendor model for Total Employee Performance (more »). New frontiers in Organisational Structures: the Italian model of "small enterprises in the enterprise", or "small and simple is beautiful".
Is job satisfaction a myth ? Movie time: people at work and job satisfaction. Why and how world-class enterprises are built on high levels of people job satisfaction.
The importance of Top Management commitment for real improvement in Performance through the World-Class Manufacturing approach. The second industrial revolution: how to get ready for the years 2000 challenges.
Duration: 32 hours (typical)
This very comprehensive and intensive course is an in-depth, "hands-on" presentation of the World-Class Manufacturing scenario.
It illustrates the cultural prerequisites necessary to switch over to world-class status, as well as the operational disciplines that should be deployed and applied in a high calibre manufacturing concern.
This course is tailored:
- to make participants aware of the strategic importance of aiming at high levels of Performance in a "Global Market" situation
- to make participants acquainted with those principles required to understand, measure, self-assess and monitor Industrial Performance
- to give delegates an in depth appreciation of the "state-of-the-art" philosophy, disciplines and techniques available to enable every manufacturing enterprise to perform at world-class level, and illustrate principles and methods that can and should be applied in factories of all types and sizes to achieve continuous Performance improvements
- to stress the importance of an integrated, holistic approach to Performance, with emphasis on achieving short, medium and long term goals
- and to highlight the necessity of a strong and modern corporate industrial culture as a prerequisite to direct any manufacturing enterprise towards new performing targets
This course is very interactive and supplemented with abundant practical exercises and case studies
The course is designed for Entrepreneurs, Company Owners, Managing Directors, General Managers, and high level Managers (Quality Managers, Operations Managers, Production Managers, Plant and Maintenance Managers, Commercial and Marketing Managers, Human Resources Managers.....) from the Manufacturing Industry.
A 0,5-day introductory workshop on WCM is also offered. For details please click here.
You are welcome to request further clarifications about this course - please be as specific as possible. Just contact Carlo Scodanibbio
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