Lean Manufacturing Training

• Long lead times, high WIP and bottlenecks that create late deliveries and excess cost.
• Unstable processes with frequent changeovers and variable cycle times.
• Lack of standard work and visual control, leading to rework and firefighting.
• Inefficient internal logistics with poor material flow, stockouts or overstock.
• Planning that is disconnected from real capacity and customer demand.
• Limited use of data and analytics to prioritize improvement and sustain results.

This training is designed for operations teams who want to implement Lean across production and internal logistics. It is ideal for plant directors, operations managers, production and industrial engineers, logistics and planning managers, area supervisors and continuous improvement leaders.

• Lean Manufacturing model: Understand the principles that connect value, flow, pull, leveling, standard work and daily problem solving.
• Production flow: Design end-to-end flow that reduces WIP and lead time while increasing throughput and stability. 
• Layout and line design: Create cell and line layouts that minimize motion and transport and support one-piece flow.
• Standard work: Define best-known methods, cycle times and work balance to ensure safety, quality and repeatability.
• SMED (quick changeover): Apply a structured method to separate internal and external activities and cut setup times.
• Low-cost automation: Introduce simple, robust devices and jigs that eliminate waste without heavy capital spend.
• Internal logistics flow: Synchronize material movement with production to ensure the right part, right place, right time.
• Supermarkets: Use controlled inventory points to decouple processes and stabilize supply.
• Mizusumashi (tugger trains): Design milk run routes and frequencies that keep lines supplied with minimal handling.
• Synchronization (Kanban/Junjo): Implement card or electronic signals that trigger replenishment and sequence delivery.
• Leveling and pull planning: Apply Heijunka and pull plans to smooth demand, reduce variability and support stable schedules. 
• Industry 4.0 and Kaizen Analytics in production: Explore practical features and applications that turn shop-floor data into action and sustain gains.
• Simulation exercises: Hands-on simulations that demonstrate flow design, Kanban sizing, SMED and leveling decisions.
• Case studies: Real examples from multiple industries showing measurable improvements in lead time, productivity and cost.

• Build flow using layout, work balance and standard work to reduce WIP and lead time.
• Cut changeover times with SMED and stabilize output with Heijunka and pull production.
• Design efficient internal logistics with supermarkets, tugger routes and Kanban.
• Connect planning with real capacity and demand to improve service and inventory.
• Use Kaizen daily management and analytics to prioritize problems and sustain results.
• Lead cross-functional collaboration between production and logistics for reliable delivery and continuous improvement.