Production
and Inventory Control Cluster
Consistent Work Methods and Build to Demand
This module introduces participants to two major
concepts in modern manufacturing: achieving and
applying consistent work methods and "build to
demand." Participants design standardized work
methods, processes, and motions. They design a
work cell, a powerful tool for implementing "build
to demand" and propose a process flow to meet
customer expectations.
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Module
Equipment Selection
Based on insights from industry experts,
Equipment Selection introduces participants
to the critical steps in the selection process:
analysis of pertinent data, tangible and intangible
cost considerations, potential income, and timeliness
to market. A final activity incorporates all the
factors into a real world selection process similar
to one participants might encounter on the job.
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Module
Introduction to Just-in-Time (JIT)
Participants learn the basic concepts
of just-in-time and the importance of just-in-time
tools for improving production processes. Through
hands-on activities, participants experience the
difference between just-in-time and a traditional
manufacturing approach.
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Module
Kanban and Pull Systems
By applying kanban and pull systems principles
and tools to real-world problems, participants
experience firsthand the difference between pull
systems and the more traditional push system.
Participants also learn to identify specific constraints
(bottlenecks) on throughput for a given manufacturing
process.
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Module
Manufacturing Facilities Design
In Manufacturing Facilities Design,
participants explore modern facility layout methods
that promote one-piece flow and lean production.
They also develop skill in selecting appropriate
material handling equipment for manufacturing
operations.
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Module
Manufacturing Resource Planning
Manufacturing Resource Planning
(MRP) teaches participants about basic material
requirements planning and introduces them to manufacturing
resource planning in a lean manufacturing environment.
They become familiar with the bill of materials,
basic MRP logic, capacity requirement planning,
cost and throughput, company operations with MRP
II, accounting and cost system implications, and
MRP II system implementation issues.
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Module
Manufacturing Work Cell Design
This module focuses on the design and
implementation of work cells to accomplish lean
production operations that balance machine processes,
part handling between stations, and the actions
of operators in a smooth, efficient, and ergonomically
safe manner.
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Module
Principles of Production and Inventory Control
Participants describe types of inventory
and their costs, how they relate to manufacturing
operations, and techniques for inventory management.
By comparing the concepts of MRP/EOQ techniques
with the theory of constraints, just-in-time,
and lean manufacturing, participants investigate
the impact of each on profitability.
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Module
Process Flow and Lead Time Reduction
Through guided discovery, participants
learn the importance of effective work flow and
short lead times in manufacturing operations,
as well as how to identify and eliminate waste.
This module also gives participants the opportunity
to analyze setups and changeovers and to design
processes for rapid setups and changeovers.
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Module
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