Lean Manufacturing & Total Productive Maintenance (Tpm)

Unlock the power of Lean Manufacturing tools, SMED, JIT, and Total Productive Maintenance (TPM) to optimize production.

What you'll learn

Foundations of Lean Manufacturing: Students will understand the key principles of Lean Manufacturing and the critical steps involved in its implementation.

Lean Tools and Techniques: The course will introduce several Lean tools such as SEITON (organization), SEISO (cleaning), SEIKETSU (standardization), SHITSUK.

Single-Minute Exchange of Die (SMED): Students will gain a thorough understanding of SMED, a technique used to reduce setup time and increase production.

Value Stream Mapping (VSM): This technique helps in visualizing and improving the flow of materials and information across the production process.

Just-In-Time (JIT) Production: Students will understand the principles of JIT, which aims to reduce inventory levels and improve product flow.

Kanban Production Control System: Students will learn how the Kanban system works to regulate production and inventory levels.

Total Productive Maintenance (TPM): Students will dive into the concept of TPM, focusing on how it helps maintain and improve the performance of equipment.

Overall Equipment Efficiency (OEE): Students will learn how to calculate and use OEE to measure and improve the performance of manufacturing equipment.

Requirements

Basic Knowledge of Manufacturing Processes: A general understanding of manufacturing systems and processes will be helpful in grasping the Lean principles, tools, and techniques discussed in the course.

Interest in Operational Efficiency: The course is ideal for those interested in improving production efficiency, reducing waste, and learning about Lean methodologies in manufacturing settings.

No Specific Software or Tools Required: While no specialized software is required, an interest in applying concepts like value stream mapping and Kanban to real-world processes is beneficial.

Description

This course covers the essential principles and techniques of Lean Manufacturing and Total Productive Maintenance (TPM). Designed to equip you with practical knowledge, it delves into Lean tools, the steps for implementing SMED (Single-Minute Exchange of Die), JIT (Just in Time), and the fundamental pillars of TPM, ensuring your organization achieves peak efficiency, reduced waste, and continuous improvement. From value stream mapping to Kanban and equipment optimization, this course is perfect for professionals seeking to enhance production processes, minimize downtime, and drive quality improvements in their manufacturing operations.Section 1: Lean Manufacturing System - Tools and TechniquesThis section introduces Lean Manufacturing, focusing on essential tools and their implementation. You will begin with a basic understanding of Lean and its steps for successful implementation. The section covers key Lean tools like SEITON (organization), SEISO (cleaning), SEIKETSU (standardization), and SHITSUKE (discipline), which are integral in creating an efficient and waste-free production environment. The goal is to equip you with the necessary techniques to streamline processes and achieve operational excellence.Section 2: Lean Manufacturing System - SMED, JITDive deeper into SMED (Single-Minute Exchange of Die) and Just-In-Time (JIT) systems in this section. Learn how SMED reduces setup time to increase production flexibility and how JIT minimizes inventory while improving process flow. You'll also explore the value stream mapping technique to visualize and improve production processes, with a focus on the Kanban system for efficient production control. The section concludes with the benefits of implementing JIT and how it can lead to significant cost savings and improved productivity.Section 3: Total Productive Maintenance (TPM)In this section, you’ll gain a strong understanding of Total Productive Maintenance (TPM) and its application in manufacturing environments. We’ll explore the types of maintenance, including preventive, predictive, and corrective, and how they contribute to the overall efficiency of machinery. The concept of Overall Equipment Efficiency (OEE) is discussed to help track and improve machine performance. Key TPM pillars such as Quality Maintenance and Safety, Health, and Environment will be covered to ensure a holistic approach to equipment care, enhancing both productivity and workplace safety.Conclusion:By the end of this course, you will have a deep understanding of Lean Manufacturing systems, including crucial tools like SMED, JIT, and value stream mapping, and their practical application to improve production efficiency. You will also be equipped with the knowledge of Total Productive Maintenance to enhance equipment reliability, reduce downtime, and ensure a safer working environment. Whether you are looking to optimize your manufacturing processes, reduce waste, or ensure maximum productivity, this course will provide the essential skills and knowledge to drive continuous improvement and operational success.

Overview

Section 1: Lean Manufacturing System- Tools and Techniques

Lecture 1 Introduction to Lean Manufacturing System

Lecture 2 Steps of lean implementation

Lecture 3 Types of Lean tools

Lecture 4 Lean Tool- SEITON

Lecture 5 Lean Tools & SEISO, SEIKETSU and SHITSUKE

Section 2: Lean Manufacturing System- SMED, JIT

Lecture 6 Introduction to SMED

Lecture 7 Steps 1, 2 & 3 in SMED

Lecture 8 Steps 4,5, 6 & 7 in SMED

Lecture 9 Introduction to value stream mapping

Lecture 10 Principles and Symbols

Lecture 11 More on Value stream mapping

Lecture 12 Elements of JITsystem

Lecture 13 Kanban production control system

Lecture 14 Example on Kanban system

Lecture 15 Benefits & Implementation of JIT

Section 3: Total Productive Maintenance (TPM)

Lecture 16 TPM Introduction

Lecture 17 Types of Maintenance

Lecture 18 Overall equipment efficiency

Lecture 19 Pillars of TPM

Lecture 20 Quality Maintenance Pillar

Lecture 21 Safety, Health and Environment Pillar

Manufacturing Professionals: Individuals working in manufacturing environments who want to understand and implement Lean Manufacturing techniques, Total Productive Maintenance (TPM), and Just-In-Time (JIT) systems to improve efficiency, reduce waste, and optimize production processes.,Operations Managers and Supervisors: Professionals who oversee manufacturing operations and are looking to improve productivity, reduce downtime, and enhance the overall efficiency of their teams and processes.,Quality Assurance and Process Improvement Specialists: Those involved in quality management, process improvement, or continuous improvement initiatives who want to deepen their understanding of Lean tools like SMED, Kanban, and value stream mapping to improve production systems.,Industrial Engineers: Engineers focusing on improving manufacturing systems and processes, aiming to apply Lean and TPM principles to design and optimize workflows.,Lean Consultants and Trainers: Those interested in teaching or consulting on Lean methodologies and practices, looking to enhance their knowledge of Lean tools and techniques for various industries.