Process Kanban in Final Assembly, Kaizen, Quality Inspection, Heijunka Synchronization with the Customer, Visual Factory Management and Lead-time Reduction - Course

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Course summary and learning objectives:
A business problem is a business problem, and it needs to be fixed, else the business might fail. This course offers well proven methods, tools and technologies to solve business problems and make factories and organizations work better. The methodologies taught in this course can be applied to any business. Understanding the application of these methods and tools to various improvement opportunities is the key to success. We introduce and discuss with many multimedia teaching and learning resources the following: Kanban, a pull system. This represents a method of regulating the flow of goods both within the factory, as well as with outside suppliers and customers. Kanban is a scheduling system for lean manufacturing and just-in-time manufacturing (JIT), applicable to many other industries too. Kanban is an inventory-control system to control the supply chain. Kanban improves process efficiency. Lean manufacturing or lean production, is a systematic method for waste reduction without sacrificing productivity. Lean also takes into account waste created through overburden, and through unevenness in work loads. Lean and kaizen together offer a simplified approach to process improvement. Since there are processes in any industry, these methods apply to a wide range of businesses. Lean is a methodology that eliminates waste and boosts efficiency. Kaizen means continuous improvement. Lean kaizen helps you get rid of waste and continuously implement best practices. The term “visual factory” refers to an approach to lean manufacturing processes based on visual information throughout the workplace. Visual indicators, displays and controls used throughout manufacturing plants improve communication of information. Visual tools also boost productivity by giving employees the information they need, where and when they need it. Visual management is one of the lean techniques designed so that anyone entering a work place, even those who are unfamiliar with the processes, can rapidly understand them. Operators can also understand and see what is under control and what isn't. Heijunka means level scheduling. This is a form of production scheduling that purposely manufactures in much smaller batches by sequencing (mixing) product variants within the same process. In combination, the above methods and others can be applied to any business improvement activity, anywhere in the world. This class offers a good overview of modern principles how to make a factory prosper, offer great service to the customers as well as well paying jobs for its employees. It also discusses several USA, Japanese, European, Asian and othe international case studies in detail. Students in this course will become problem solvers and be able to understand the underlying principles, as well as apply some of the learned methods, tools and technologies in real-world, practical situations. The learned methods will be highly beneficial not just to engineers, but also to designers of systems.

Levels offered:
Undergraduate engineering, graduate, and/or professional industrial level for engineering, IS/IT (Information Systems / Information Technology), and/or Management, including MBAs, Master of Business Administration. We also welcome administrators and managers in our programs who are keen to understand and improve systems, any systems, processes, factories, organizations, and others.

What do the instructors want students to be able to do at the end of the course? Instructors want the students to understand the analytical concepts, methods, tools and technologies presented in this course, as well as apply the learned knowledge to solve practical real-world problems.

How students’ abilities will be measured during the course, that will provide reliable evidence that the students are learning?
Every student in this class has to set up their own virtual company on the internet. This can be done for free, using the internet and free software tools. This student authored and controlled web site will act as a knowledge depository and management resource, as well as a communication tool, where students document their assignments during the course. (This open, internet-based, not passworded student created web site is also an excellent portfolio for each student. This is very valuable when looking for a good job.)

How students’ abilities will be measured at the end of this course, that will provide reliable evidence that the students have mastered the subject?
Students in this course are continually assessed. They have to complete several assignments in collaboration with the instructor, as well as other students in the class. Each student works on their own virtual companies, in different assignments, nevertheless the underlying analytical foundation, as well as the educational goals reflect the topic of the class and are the same for every one of them. The collection of these web-documented assignments will be graded by the instructor and this will provide the final grade for the course. There won’t be a final exam, since this is a continually assessed course.

Delivery mode:
The above programs can run in live or in eLearning (i.e. distance learning) mode over the internet.

Duration:
The length of this course can be 1 day executive summary, 3 days introduction, or 5 days more in-depth, advanced level. Also, in cases when universities want to run such programs of study, the duration of the program can be extended to a 15 week long period, about 3 hrs a week group learning and 3 hrs a week independent study (per student), with additional assessment / examination work included. (This will make the course compatible with typical modular USA university / college courses.)

On-line internet support:
This course is supported by an internationally known professional instructor / consultant, including 7 days a week 12 hrs a day email support for 3 months, and optional on-site lecturing / tutoring / consulting (if there is such an arrangement). Please note, that this program of study has a world-class quality interactive multimedia content, that is frequently updated by professionals. This makes this course fresh and up-to-date every time it runs.

Delivery style:
This course is delivered in interactive, informal workshop style over the internet or in live mode, with active learning, with lots of excellent analytical methods and practical industrial case studies using interactive multimedia text, images, videos, optional interactive multimedia eBooks and active code to calculate with. The practical case studies are from the USA, Europe, Asia, Pacific Rim and Japan, offering excellent teaching / learning quality and effectiveness.

Licensing arrangements:
The above courses can also be licensed to be run by third parties, nevertheless these third parties have to be carefully reviewed and certified to do so. This is important to maintain the exceptionally high quality levels of this type of program using various modules of our interactive multimedia resource library.).

Also note, that we can deliver custom designed programs based on customer requirements. The topics, the level, and the duration, the delivery mode of our modules can be custom designed by a group of learners, or their organizations (i.e. the customers). These custom designed programs can have a mix of the above topics, as well as other, new topics, as required by the customer.

Please note, that we have over 33 years of international professional experience. We are a USA -based group of professionals, and that our programs are continuously updated and expanded based on customer requirements in the USA, Europa, Asia, Africa, and elsewhere.