Technical and Financial Aspects of Lean Manufacturing

Introduction:

A lean manufacturing system seeks to increase productivity while minimizing waste in manufacturing processes, operating as an overarching operational philosophy. Lean Manufacturing emphasizes constant improvement and the removal of activities and processes that do not add value. Understanding lean practices and principles is particularly beneficial in a competitive business environment, helping organizations achieve their objectives more effectively.

This course, Lean Manufacturing Essentials, Technical, and Financial, provides an in-depth exploration of both technical and financial aspects of lean manufacturing. A thorough comprehension of these areas is crucial for the successful implementation and maintenance of lean practices in any organization.

The course content will cover the technical practices used in lean manufacturing and the market forces that influence them. Participants will gain insights into how technical and financial aspects intersect to enhance the effective application of lean manufacturing concepts, aiming to transform organizations into more profitable entities with improved people, processes, and properties.

Objectives:

At the end of this course, participants will be able to:

• Understand the technical foundation of lean manufacturing principles.
• Identify and eliminate waste within manufacturing systems.
• Comprehend the costs associated with implementing lean manufacturing and their impact on organizational health.
• Improve the quality and efficiency of production processes by modifying methods.
• Use relevant financial data to inform operational decisions in a lean manner.
• Develop systems that promote continual improvement using lean practices.
• Integrate business economics with technical means to support lean manufacturing.
• Gain practical knowledge to actively participate in and lead lean initiatives in the workplace.

Training Methodology:

• Use of practical tools
• Financial analysis exercises
• Learning by doing process improvement
• Peer work
• Step-by-step guidance from an instructor
• Gathering of information and feedback

Course Outline:

Unit 1: Introduction to Lean Manufacturing Principles

• Definition, principles, and concepts of lean manufacturing
• Critical concepts such as waste elimination and sustained improvement
• Importance of minimizing and improving waste
• Analysis of case studies on successful lean practices in various industries
• Introduction to basic lean tools, concepts, and approaches (e.g., 5S, Kanban, Poka-Yoke)

Unit 2: Technical Foundations of Lean Manufacturing

• Various process improvement methods
• Study of manufacturing tools based on lean practices and manufacturing types
• Essence of lean production systems and their components
• Practical activities to apply lean qualities and identify areas needing improvement
• Assessment of new improvements in production efficiency and automation

Unit 3: Financial Analysis for Lean Manufacturing

• Basic financial concepts related to lean manufacturing (e.g., total cost of ownership, return on investment)
• Analysis of overhead costs and their reduction in a lean context
• Budgeting and forecasting compatible with lean operations
• Case studies on the financial benefits of lean practices
• Measuring and defending the perceived value from lean initiatives

Unit 4: Integration of Technical and Financial Strategies

• Linkage between theory and practice in lean manufacturing
• Combining technical and financial goals within a company
• Case studies on successful integration of engineering and management
• Specialization of concepts and strategies for interdisciplinary teams
• Hands-on activities to develop and implement combined engineering and financial approaches

Unit 5: Implementing and Sustaining Lean Practices

• Step-by-step procedures for sustaining a lean culture in manufacturing processes
• Addressing resistance to change within the organization
• Strategies for sustaining lean initiatives through employee engagement and culture change
• Leadership principles in lean management and best practices
• Continuous improvement strategies and maintaining lean practices