Page 261 - How To Implement Lean Manufacturing

Using the Pr escription—Thr ee Case Studies 239

The Educational Evaluation
The educational needs were quite extensive and we began immediately to train.

Introductory Training
An introduction to Lean manufacturing was given to everyone by Human Resources as
part of a two-hour awareness training, which also included a review of the implementa-
tion plan.

Management Training
Management was given training over a one-month period, with each session lasting
roughly four hours. Topics included:
• The role of management in Lean
• The House of Lean
• Introduction to OEE
Other Training
Specific skills training was given to those involved, primarily engineers and supervi-
sors, in the areas of:
• The House of Lean
• Introduction to OEE
• OEE calculations for engineers, OEE strategy
• SPC, focus on control charting
• MSA
• TPM
• Kanban design and calculation
• Cycle, buffer, and safety stock calculations
• How to level processes and heijunka board design

Just How Was the “Rest of the Prescription” Managed
I have summarized The Second Prescription here for your reference. It is an eight-step
Prescription for the Lean Project, which includes the following measures:
1. Assess the three fundamental issues to cultural change.
2. Complete a systemwide evaluation of the present manufacturing system (outlined
in Chap. 19 and detailed in Chaps. 6 and 7).
3. Perform an educational evaluation of the workforce.
4. Document the current condition of the value stream.
5. Redesign to reduce waste. (This is simply a summary of Chap. 7.)
6. Evaluate and determine the goals for this line.
7. Implement the kaizen activities.
8. Following the changes, evaluate the new present state, stress the system, and
then return to step 4.