Essential Lean Manufacturing for Management Consultants

In this lecture I will share some info on who am I and what is my experience

Most treat production as a black-box but if you want to be a great consultant you  will have to get into details. In this lecture I will show you why it makes sense to go deeper into production and e I will talk about the important issues that you will master in this course

In this lecture I will talk about the important issues that you will master in this course

Here I will show you what to do if a blurry image appears

Here I will show you how to find additional resources attached to the coruse like Excel files, presentations, links etc.

Most treat production as a black-box but if you want to be a great consultant you  will have to get into details. In this chapter I will show you how to improve production results with simple methods and techniques and what it means in practice

Due to differences in waste we only use 5% to create value. In this lecture, I will show you 7 different types of waste that may occur at your business

In production, you will know far less than your customer’s team so you have to use smart ways to get to the bottom of things. 5 Why is one of such methods. In this lecture, I will show you how to use it in practice

We show here how to use the so-called OEE (Overall Equipment Efficiency) Analysis that shows you how efficient you are in using your resources. It is very useful for checking whether you use well machines and equipment/

In every company, you have bottlenecks that limit your ability to go forward and deliver more goods and services. Here I will show you how to estimate what is the impact for the whole system and how you can remove improve them. 

Now imagine that you were asked to increase the production capacity of a factory. Try also to calculate the financial impact of the proposed scenarios. Before we look at specific scenarios we have to discuss 2 issues

• What the production capacity depends on?

• How to calculate monthly production capacity

First let’s see what the production depends on assuming there is just 1 production stage

We said that the production generally speaking depends on 3 drivers. Now let’s see how it looks like for the whole month

Here we will discuss the sceanarios that we will analyze later

Here we will discuss the available data that we will use to solve the case study

In every company you have bottlenecks that limit your ability to go forward and deliver more goods and services. Here I will show you how to estimate what is the impact for the whole system and how you can remove improve them. I will use simple production example to show you the effect on the whole system. You will see how the bottleneck can shift from 1 shift to another. You will also learn how to prioritize where it make sense to invest to get the best results.

Before doing this lecture I strongly encourage you first to take the OEE lecture – we use the OEE concept here so if you are not familiar with it please start with OEE lecture as a warm-up.

In this lecture we will see how you can present the result of the analysis in a for of graphs

You quite often have situations when people perform at a different pace and with different results. You have to standardize them.

Here I will show you in Excel the effect on standarization

5S in short is about cleaning your working station, putting everything in order and keeping it this way I will show you the stages, examples of 5S and how to check whether the business has truly implemented 5S

Here I show how to calculated the impact of 5S on cost in Excel

We are very fast to acquire, buy and collect because even if we do not use it know at some point (usually very distant in the future) specific thing may prove to be  lifesaving.  Most often, the staff we collect we do not use more than once (80/20 rules come into play. In this lecture I will show you how to get rid of unused things it in practice

Kanban is a way in which you can drastically limit work in progress. I will show you in this lecture what it is and how it looks like in practice

I will show you how to calculate the impact of Kanban in Excel

In this lecture I will show you how to take advantage of periods of lower activities using the so called Kanban

Zero defect rules is not about making zero mistakes. It is about finding mistakes as soon as possible and eliminating them. In this lecture I will show what it is and how to use it in practice

I will show you how to calculate the impact of universal workers in Excel

If you have specialized workers you end-up not using most of available resources. I will show you what you can achieve by having a more universal workers

Quite often you have one operator per one machine. This is often not efficient as machines just need feeding in the goods. 

I will show you how to calculate in Excel the impact of making the workers operate on more than 2 machines at the same time 

The ideal in production is the so called continuous flow -every go smoothly and fast. Products are being produced      fast and cheap. In this section I will tell you how to achieve it.

Using a sandwich factory I will show you the mistakes people do when they try to create a continuous flow

I will continue our example of sandwich factory. I will show you how the continuous flow should look like

I will continue our example of sandwich factory. We add the Kanban to the continuous flow

I show here example of continuous flow in services

Sometimes it makes sense to have instead of continuous flow the so called smart batching. Here we continue the previous example from service company to show how it could look like

I will show you how to use similar to OEE concept on people the so called Overall Labor Efficiency that shows you what is the potential for improving things done by people

Before you start analyzing the waste you have to somehow group it by stages of occurrence and type of waste. I will show you in this lecture how you can approach this subject

Imagine that you work for a plywood firm with 3 factories and you have to decrease waste. A few information about he firm:

They have 3 plants

• They have different waste level

• You can find waste: in too big level of wood usage or plywood quality

• Estimate the potential impact on profit and cash

  
  

In this lecture we will be solving the previously introduced case study

One of the ways to make the set-ups shorter is the so called SMED technique. I will show you how to use it

Imagine that you are in a fish factory.  How much money are you loosing and how you can improve it

In this lecture I show you the solution to the case you had to solve in the previous lecture

Apart from production people you will have a lot of so called maintenance guys that are fixing the machines. For this are we used the so called TPM

In more and more cases you have to find way to replace or support people with machines to lower down production costs

One of the biggest problem for efficiency is the so called Parkinson’s Law – Work expand so as to fill the time available for its completion. People when asked to evaluate the time certain things will take build in buffers. One of the ways to deal with it is the so called Critical chain. Here I will show you what it is

Apart from optimizing the production you have to think strategically and know when you have to add new capacity / factory. In this section I will show you how you can do that

Here I will show you how to manage capacity depending on your industry and demand forecast. 

Locations of some factories depends on the so called supplier catchment area. You are looking for area where you have sufficient amount of resources or suppliers. Here we will see how catchment area influences decision on capacities

The customer catchment area is important in picking the right location for the factory. Both B2B as well as B2C. Here I will show you how to approach this subject

In this lecture we show how you can measure and analyze what is the maximal reach of your B2B bussiness having in mind transportation costs and markups. We will provide you with fast way to identify potential customers and measure your targeted price on a specific foreign market

In this lecture you will learn how to calculate optimal batches and how to estimate savings when comparing to actuals batches. We will use his an example of juice producer

2-stage production planning (planning for assembling and bundles). In many cases you have to first prepare the components and then on the basis of this produce the end product. This requires certain amount of additional planning, especially taking into account that the same component can be in different end-products. I will show you here on the basis of example of cosmetics producer how to create such a production plan, assuming optimal production batches for components and taking into account the inventories.

In this secgtion I show you how to optimize processes in the store. I will use here real case of a company from home improvement / DIY sector. You will get also the model we used to calculate costs

Workshop was very important as I was getting a team that I did not know and that did not trust me. On top of that they did not know how to optimize processes. I will show you in this sections what were the goals of the workshop 

In this section you will see what kind of goals were presented to the project team

The team had no previous experience in process optimization. In this section I will show you the techniques  that we were using to optimize the processes 

Here you will find a short introduction to Lean manufacturing.  

Here you will find a short introduction to theory of constraints 

Here you will find a short introduction to Queuing problem 

Here you will find a short introduction to OEE 

Here I will show you how in groups for chosen process the team has chosen the KPIs and cost drivers 

In this lecture I will show you an example of 1 process that was optimized with the team. I used this to show them the proper way of defining the KPIs, cost drivers and optimizing the process using this data

Finally, during the workshop I show them the timeline of the project to get confirm that the project is doable within this ambitions timeline 

In section 4 I show you how to optimize      processes in the store. I will use here real case of a company from home      improvement / DIY sector. You will get also the model we used to calculate      cost

In this lecture I will show you some information on what we achieved during the process optimization and how the test store looked like

Here I will show you how we optimized the process of changing prices in the store and what savings we managed to generate

Here I will show you how we optimized the process of shelf replenishment in the store and what savings we managed to generate

Here I will show you how we optimized the process of advising customers in the store and what savings we managed to generate

Here I will show you how we optimized the process at cash till and info point in the store and what savings we managed to generate

Here I will show you what other potential improvements we suggested in order to sell new projects

In this lecture I will show the estimation of cost

In this lecture I will show the estimation of costs and savings achieved during the project

Imagine that you were asked to prepare an analysis to determine how the rearranging of the main office of the drugstore chain company will help reduce costs.

In this lecture, I will show you the solution to the previously introduced case study.