Creating Level Pull (1 Day Class)
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Description:
Creating Level Pull moves beyond making improvements in the value stream of an individual product family. This workshop addresses how to tie together the flow of all product families through a facility by implementing a lean production control system that establishes the conditions for superior performance.
Please note that this workshop is designed to meet the needs of manufacturing audiences.
Benefits:
Level demand and pull systems are key factors in Toyota’s success, but few companies have truly achieved this level of performance. This workshop will equip you with all the basic tools Toyota uses to create level pull in almost any kind of facility.
At the end of this workshop you should be able to:
- Determine true demand and what parts to hold in finished goods
- Establish where to schedule value streams
- Design material and information flow from the pacemaker process to upstream processes
- Expand the pull system plant-wide
This workshop will equip you with the knowledge of how to create a level pull system of production across a facility to achieve:
- Reduction of manufacturing lead time of 20-90 percent
- Improvement in on-time delivery up to 100 percent
- Improvement in inventory turns
- Reduced overtime and expediting of material
- Improved labor productivity for direct and indirect labor as much as 30 percent
Note: This workshop will not address:
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The implementation of flow in a cell or from a purchased parts market to an assembly cell
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Traditional scheduling matters such as capacity planning, forecasting, master production scheduling, or material requirements planning
Course Outline:
Through instruction, discussion, a simulation, and in-class exercises this workshop will explain how to implement and sustain true flow, pull, and leveled production in a facility from the customer demand point of view backwards through the entire facility from finished goods back to raw materials.
Specific topics include:
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When to build-to-stock versus build-to-order
- How to use finish goods inventory to buffer demand
- How to select the pacemaker process for the facility
- How to level the schedule at the pacemaker process
- How to deliver instructions to the pacemaker process
- When to flow material in the plant one-by-one versus producing in small batches
- How to employ replenishment schedule principles versus sequential pull
- How to use production instruction kanban, parts withdrawal kanban, and signal kanban
- How to size supermarkets for internal components
- How to set lot sizes for batch processes
- How to set a "pitch" interval for production instruction
- How to spread level and pull production across the entire facility
Who Should Attend:
Please note that this workshop is designed for manufacturing audiences.
- Production control personnel, manufacturing and engineering specialists and management, purchasing, and lean change agents
- Any industry with multi-step processes with at least some demand for standard products
- An organization that is advanced in their lean journey, has mastered basic lean tools and concepts, and has initiated flow somewhere in the organization (either in a cell or elsewhere in the value stream)
Suggested Reading:
For this workshop, you need a solid foundation of lean knowledge through both training and hands-on implementation in such basic tools as waste identification and elimination, 5S, and problem solving. Your shop floor processes should be stable and your organization should have started to implement flow (where possible). You need an understanding of lean terms and concepts as described in Lean Thinking by Jim Womack and Dan Jones. Since the workshop is based on the Lean Enterprise Institute's book Creating Level Pull by Art Smalley, we suggest that you read this book in order to maximize your learning outcomes.
To maximize your learning experience we recommend that prior to attending this program you take following workshop or have a good understanding of the concepts presented within it.
Price: $800.00 ($700.00 if the participant is taking 2 or more workshops at one location)
Sign up to be notified when this workshop is available in your area.