LEAN FABRIKA

TRAINING PORTFOLIO
START
Manager 2
(6 Days)
5S
The 5S Method, is one of the LEAN philosophy cornerstones, it
belongs to point KAIZEN methods. It is a workplace organization
method leading to the elimination of waste, increased productivity,
and workplace safety. It is typically the first method to be
implemented while introducing the LEAN philosophy. The course
participants will begin by getting acquainted with the basics of the
method. They will learn to identify 7 types of waste. Within a
simulation, they will apply the 5S implementation through a
“Numeric Chaos” game.
1
PEP
Product development process is a complex process describing particular phases
and steps of the product development up to product launch on the market. The
objective of the PEP workshop is to strengthen knowledge of product genesis
and quality assurance processes. Further the aim is to give participants
awareness about critical success factors which may have a significant impact
on product quality already before the start of production. During the
simulation participants are applying selected procedures and methods
relevant for the product development process and industrialization and
are essential for successful serial production and launch of the
first-rate product on the market.
9
Lean ERP
The LEAN ERP training program is designed for those who actively search for a way to optimize the
use of ERP systems while implementing LEAN principles. The objective of the course is to introduce
LEAN topics such as production management pull principles, SMED, TPM and to make them accessible
for effective use with the support of an ERP system. In the simulation, the course participants will
try various settings necessary for optimum ERP performance. Based on the preformed simulation,
the participants will understand the practical differences and contradictions
in properties of ERP systems and LEAN production
requirements. As a result, the participants will
gain practical skills due to which they will be
able to set ERP systems and effectively use ERP
processes in accordance to the requirements of
the LEAN production theory.
START
10
2
3
4
Manager 1
(4 Days)
Engineer
(2 Days)
STD
A standardized workplace is a strong tool belonging to the
LEAN philosophy. Having the current state of the workplace
and the working procedure well described and documented
is the basis for continuous improvement – KAIZEN. By
analyzing, improving and documenting the current state,
we create a new standard which becomes a foundation
for another improvement (KAIZEN). This is also the
purpose and content of the course. At the end, we
simulate, the new and improved production process
designed by the participants.
PUSH AND PULL
The LEAN philosophy represents a crucial change in thinking:
from mass production managed by big batches and safety supplies
(PUSH) to a production managed by the customer’s consumption
(PULL) – ideally heading towards “one piece flow“ (OPF). The
objective of the course is to identify the push and pull managing
principles, the basic theory of planning strategy, the ABC/XYZ
analyses, and, within the a production simulation, the gradual
transition from push to pull by implementation of KANBAN,
FIFO, SUPERMARKET, and OPF.
SMED
SMED (Single Minute Exchange of Die) is
one of the LEAN philosophy methods. This
method focuses on the changeover optimization.
It defines 8 steps to achieve an optimized
changeover. Course participants learn these steps
theoretically and practically through an implementation
of a changeover simulation. They try to identify waste and
the external changeover processes, seek a solution for internal
changeover optimizations, and document a new process. This will
formulate a new standard. The simulation of a new process is finalized
with a competition between 2 teams.
ROM
ROI “Operations Folge” method is a method based on predefined
times. It is used to analyze and assess production and logistics
activities involving human interaction – both current and future.
Calculating required assembly times is a typical use of this method.
Within the course, the participants will get acquainted with time
management and the basics of the ROM methodology. They will
perform practical implementations of the method on various levels
of product complexity (basic move, simple activity, complex
operation and complex product).
TPM
The course consists of specific topics related to maintenance,
such as TPM (Total Productive Maintenance), basic maintenance
strategies, introduction of the LEAN Maintenance System, OEE,
and autonomous maintenance. Applying a systematic approach,
you will learn how to identify the key points of maintenance,
to identify the correct strategies and concepts, and visualize
what an optimal maintenance organization could look like.
Hands on experience in the simulated process is the basis for
building the required experience and expertise.
8
7
Lean Office
Completely in the sense of 5S, the first step deals with the systematic
and standardized workplace organization. The employees are
actively involved in determining the state of the organization. They
learn through a game to transfer the 5S approaches to their work
environment. Based on the experience from the first part of the
course, they will learn the methods, tools, and principles for the
optimization of administrative processes. They will also have better
sense for identifying waste in office.
6
LKW
The TRUCK PLANT is ROI’s most extensive course. It consists of
a simulation of a manufacturing process – a complete model truck
assembly. The course also provides a basis for the Value Stream
Mapping method application. The objective of the course is to
introduce the VSM method, the calculation of the lead and tact
time, the recording of the current value stream, the draft
and implementation of a future value stream – in line with the
customer’s tact time and with predefined process performance
indicators on the basis of simulated truck assembly.
5
11
13
14
SANDBOX
The purpose of the customer sandbox workshop is to provide
to client a "Lean sandbox", where participants may try to
implement various optimization scenarios for workplace
organization without affecting their own production process.
It has appeared in experience that major effectiveness of the
workshop was achieved by connection of preceding process
analysis at the client made by ROI consultants who are able
following to the analysis set up similar conditions for the
process simulation in the Lean Fabrika. The workshop is a
suitable complement of the completed lean training when
participants examine their lean knowledge and application of
the lean method in the process they know.
Silver Certificate
The graduate who gains the Silver
certification level, will be able to
independently manage projects and
continuously improve internal processes.
Gold Certificate
The graduate who gains the Gold
certification level proves to have a complex
knowledge of approaches, tools, and
methods from the LEAN management
field. This level represents the graduate’s
competency to positively influence, and
to be responsible for the development of
technologies, processes, and employees
of his company.
12 Bronz Certificate
The graduate who gains the Bronze
certification level, proves to have sufficient
knowledgeof basic principles, tools, and
methods in the LEAN management filed, that
will enable him/her to implement specific
improvements in a team effort and realize
measurable results.
FINISH