Lean Manufacturing is an essential component in modern manufacturing, and Amatrol has created a program that presents these concepts in a clear, concise methodology. Lean manufacturing is the business philosophy of improving efficiency and product quality by eliminating waste and improving production flow. It focuses on the expenditure of resources and preserving value with less work.
Amatrol’s Lean courses explore the history, evolution, and benefits of Lean; workplace organization; proper machine set-up; standardized work; value stream mapping; and topic areas such as Poka-Yoke, Kaizen, and 5S (Sort, Straighten, Shine, Standardize, Sustain).
Amatrol’s Lean Manufacturing multimedia courses engage the learner with various types of interactivity, videos, and animations to keep their focus on the task in ways that a “page-turner” type course cannot. As one example, while learning about 5S, the learner is presented with a view of an industrial manufacturing area and asked to click on conditions that violate the 5S rules. Other examples include interacting with a production cycle to see how and why different types of Kanban system are used and determining takt times for a process.
Lean Manufacturing Multimedia Courses
Lean Overview and Workplace Organization (MXLM100): An introduction to the 5S (Sort, Straighten, Shine, Standardize, Sustain) principles and how they fit into the workplace. Learners gain an understanding of each component of 5S – what each area means, why it is critical, what the requirements are to implement it, the commitment needed to keep it alive, and how it is executed in the workplace.
Introduction to Lean Manufacturing (MXLM101): Provides a good introduction for creating a Lean culture in a traditional manufacturing environment. This course explores the challenges faced by traditional companies and their production methods, describes the principles at the heart of a Lean system, and explains the concepts that must be ingrained into a company culture before Lean methods are implemented.
Introduction to 5S (MXLM102): Covers workplace organization and the steps of 5S: Sort, Straighten, Shine, Standardize, and Sustain. Within this lean manufacturing online training course, learners will study the key action steps within each 5S area to implement Lean Manufacturing processes, such as item organization, marking storage locations, outline locations, and shadow boards.
Total Productive Maintenance (MXLM103): Focuses on overall equipment effectiveness, autonomous maintenance, and maintaining equipment. Learners will study methods of predictive maintenance and preventative maintenance like equipment cleaning methods, equipment inspection methods, how to eliminate contamination sources in inaccessible areas, and testing and developing lubrication standards.
Poka-Yoke (MXLM104): Covers Zero Quality Control, Poka-Yoke systems, and Poka-Yoke devices. This course begins with the elements of Zero Quality Control, plant defect levels, types of inspection. This Lean Manufacturing course then moves to Poka-Yoke elements and methods and how Poka-Yoke systems are used in informative instructions and source instructions, as well as sensing devices used in Poka-Yoke systems.
Lean Theory (MXLM203): Focuses on the origins of Lean Theory, leadership principles in Lean Theory, the value of people in Lean Theory, and Lean Theory principles behind the tools of Just-In-Time. The course also covers relating and differentiating the Lean Production System (LPS) and the Lean Way, the steps of continuous improvement through Kaizen, the explanation and purpose of Heijunka, and goes into the environments in which standardized work succeeds and fails.
Lean Process Flow (MXLM204): Covers Lean Production, Little’s Law, maximizing resources and reducing wasteful activities, Kanban System types and operation, the purpose of inventory in a Kanban System, Lean Production scheduling, flow production, and cellular manufacturing.
Visual Workplace (MXLM205): Discusses how to use visual communication to create a clear, safe, and sustainable environment for workers, including topics like visual facility guidelines, visual machine maintenance systems, and visual observation systems. The eLearning course covers visual communication, the elements of a visual workplace, visual documentation, visual control, visual production indicators, and creating and sustaining the visual workplace.
Standardized Work (MXLM206): Begins by defining standards and explains their role in Lean Manufacturing, then discusses types and levels of standards. Learners will also study interpreting a production capacity sheet for manufacturing capacity planning, as well as how to interpret standardized work combination tables, job element sheets, and standardized work charts.
Kaizen (MXLM307): Covers concepts such as the term Kaizen and its role in manufacturing; Kaizen event planning including selection of a team, training, preparation, scheduling, and communication; Kaizen event implementation including rules, collection of data, performing a time and motion study, methods used for identifying and analyzing waste, types of reports and application; and Kaizen event examples including how to perform a 5S Kaizen event, a Bottleneck Kaizen event, and a Lead Time Reduction Kaizen event.
Value Stream Mapping (MXLM308): Covers topics like Value-Added Processes, Current State Value Stream Mapping, creating and implementing a Future State Value Stream Map, and the preparation and implementation of Value Stream Mapping.
Set-Up Reduction (MXLM409): Covers setup reduction, analyzing setup processes, internal tasks, external tasks, and streamlining changeover. This online lean manufacturing course teaches learners ways to identify and eliminate waste in order to improve quality, reduce production time, and decrease cost in order to drill down manufacturing processes to what is value added.