Lean Operations Overview

This training describes the scope, purpose and components of an effective Lean Production System. Participants learn the historical roots of Lean Manufacturing philosophy, the types of waste associated with all manufacturing processes, and the Six Pillars of a Lean Production System.

This introductory course outlines the seventeen modules that make up this curriculum. Implementation is covered, including the three stages of transitioning from traditional manufacturing methods to a Lean Production System. This module focuses on the basic concepts and principles of the Lean Manufacturing Philosophy, with an emphasis on what is necessary to successfully install Lean components in a plant.

This course will measure mastery on each of the following performance objectives:

• Describe the scope, purpose and six main characteristics of an effective Lean Production System.
• Explain typical actions and activity sequences for each of the three stages of a Lean Program implementation.
• Evaluate the seven types of waste that affect all manufacturing systems.
• Understand the critical success factors necessary for a successful Lean Production System implementation.

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The Six Pillars of Lean Production Systems

This training consists of six unique traits or supporting pillars that set them apart from most current production environments. People and companies must gain a strong understanding and vision of these pillars and how they are integrated into a comprehensive Lean Program.

The course presents each component, its definition, and an application description.

This course will measure mastery on each of the following performance objectives:

• Explain the Six Pillars of Lean Production Systems.
• Understand how these pillars support the overall effectiveness of a Lean Production System.
• Describe why each of the Six Pillars of Lean Production Systems are necessary before a pure Continuous Flow environment can exist.
• Understand the implementation process and the timeline required to install a Lean Production System.

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Systems Thinking and Problem Solving

This training focuses on systems thinking and problem solving, which are processes and techniques used when developing and implementing new business processes such as those associated with a Lean Program.

Systems thinking focuses on the global cause and effect of actions throughout an entire company or beyond. Actions or changes causing systems impact beyond a span of control must be acknowledged and understood, so communication can take place prior to the actions or changes being made.

This module describes systems thinking; including causes, effects, links and loops, and an overview of problem solving tools, when they are applied, and how they are typically used to resolve problems.

This course will measure mastery on each of the following performance objectives:

• Understand the purpose and objectives of the Systems Thinking process.
• Understand the purpose and process of problem solving.
• Become familiar with several Problem Solving Tools.
• Apply Systems Thinking and Problem Solving Tools to Lean Initiatives.

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Culture and Change Management

This training module explains how to identify and cause the changes needed to establish and maintain the new Lean culture.

A successful Lean Production System requires the installation of new processes, methods, attitudes and performance measures. As important, it requires significant change to company culture and beliefs. Key topics include the value of change, types and magnitudes of change, key actions needed to cause change and how to align company culture to a Lean Manufacturing mentality.

This course will measure mastery on each of the following performance objectives:

• Understand the definitions, varying degrees of company culture and how culture is managed both formally and informally.
• Describe traditional and Lean cultural attributes and how to assess the gap between your company culture and a Lean culture.
• Understand the change process and how to cause change through company leadership and employees.

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Lean Performance Measurements

This training shows learners how to select, define, qualify, measure, and report Lean Production System performance.

Each Lean Initiative must incorporate performance metrics that measure performance objectives and results. Key topics in this module include how to define Lean performance objectives; how to define and implement Lean performance measures, reporting methods, corrective action management, data collection and implementation considerations.

This course will measure mastery on each of the following performance objectives:

• Define the purpose, value, and components of performance measurements and a performance measurement system.
• Relate the differences between traditional performance objectives and Lean performance objectives.
• Determine Lean product line objectives and supporting performance measurements.
• Describe how to visually display and communicate Lean performance measurements.
• Link lean performance measurements to problem solving tools.

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Continuous Flow and Plant Layout

This training module describes continuous flow objectives and plant layout methods. The ultimate goal of a Lean Production System is continuous fow for all products in the plant. Continuous flow is a long-term Lean strategy that extends to all facets of the company. Achieving total continuous flow begins with a structured Lean Program implementation applying Lean tools and techniques during the transformation process.

In this course, the learner identifies steps necessary to create an optimal plant layout and design.

This course will measure mastery on each of the following performance objectives:

• Define the purpose, requirements and vision of a Continuous Flow manufacturing environment.
• Understand the steps necessary to create an optimal plant layout and design.
• Describe the strategy needed to transition from a discrete manufacturing environment to a true Continuous Flow system.

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Mapping the Value Stream

This training module describes the process, methods, and tools used to create and maintain Value Stream Maps. Learners become familiar with Lean mapping symbols and mapping techniques; and discover how mapping for a Lean environment differs from traditional mapping methods.

At the end of this course, learners will understand the importance of mapping both the flow of material and the flow of information; and will be able to document current processes using Value Stream Maps with Lean symbols.

This course will measure mastery on each of the following performance objectives:

• Understand the baseline, constrained, and optimum state Value Stream Mapping.
• Describe the purpose of the baseline, constrained, and optimum state Value Stream Mapping.
• State the objectives of the baseline, constrained, and optimum state Value Stream Mapping.
• Identify the importance and key activities of the baseline, constrained, and optimum state Value Stream Mapping.
• Understand Lean Value Stream Mapping symbols and the subsets used to map processes.
• Gather baseline documentation required as the foundation for future process improvement.
• Create a set of Baseline Value Stream Maps for a process in your company.

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Work Flow, Cell Design and Takt Time

This training module teaches the learner to evaluate product lines and manufacturing processes for cellular manufacturing applications and configure cells to be efficient and effective.

Key topics include requirements for and attributes of a manufacturing cell, demand and scheduling considerations, and typical constraints and barriers to manufacturing cells. This course also includes several examples of typical manufacturing cell configurations.

The concept of takt time, which is defined as the pace of market demand and the rate of production based on available time, is discussed. will learn how to calculate takt time through several takt time calculation examples and hands-on exercises.

This course will measure mastery on each of the following performance objectives:

• Transform a traditional manufacturing layout to Continuous Flow using Cellular Manufacturing techniques.
• Describe the purpose of transforming a traditional manufacturing layout to Continuous Flow using Cellular Manufacturing techniques.
• Identify the methods used to transform a traditional manufacturing layout to Continuous Flow using Cellular Manufacturing techniques.
• List the requirements for transforming a traditional manufacturing layout to Continuous Flow using Cellular Manufacturing techniques.
• Determine effective cellular structures and configurations.
• Explain how to conduct studies and calculations to determine effective cellular structures and configurations.
• Establish and maintain takt times for manufacturing cells.

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Machine Rightsizing & Change-Over Reduction

This training describes techniques used to select and specify the best machines for flow manufacturing and cellular manufacturing environments. Techniques used to reduce machine change-over times are also discussed.

The transition from traditional manufacturing to a Lean Production System with Continuous Flow requires utilizing flexible machines arranged in the order they are used; and change-overs taking little or no time. Continuous Flow is achieved through the implementation of a series of manufacturing cells and/or flow manufacturing lines. This course teaches learners to select and specify the right machines and resources for manufacturing cells and flow configurations. Learners also discover change-over reduction methods.

This course will measure mastery on each of the following performance objectives:

• Select and specify the right machines and resources for manufacturing cells and flow configurations.
• Understand and complete a cycle time and space reduction exercise.
• Become familiar with change-over reduction methods.

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Managing a Lean Program

This training explains how to manage a Lean Program through Lean Initiatives. Lean Initiatives are the key Lean concepts that must be in place to convert a traditional manufacturing system to a Lean Production System. These Lean Initiatives are implemented through Key Events, Training Events and Kaizen Events. Each will be explained in greater detail throughout this module.

This course will measure mastery on each of the following performance objectives:

• Establish what is required to set up an effective Lean Program.
• Show how a Lean Program is managed through Lean Initiatives.
• Describe the purpose, requirements, components and benefits of a Kaizen Event.
• Define the resources, priorities and management support needed to successfully conduct a Kaizen Event.
• Prepare a high-level Kaizen Event project plan for a defined Lean Initiative within your company.

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Line Balancing, Heijunka & Poka-Yoke

This training module explains the concepts of line balancing, Heijunka, and Poka-yoke. Activities and their interdependencies are described in this module.

This course will measure mastery on each of the following performance objectives:

• Understand line balancing.
• Describe the concepts of manufacturing line balancing.
• Explain the principles of manufacturing line balancing .
• Explain how to apply concepts and principles of manufacturing line balancing to typical manufacturing processes.
• Understand one-piece flow.
• Explain the purpose of one-piece flow.
• Identify proper methods of one-piece flow.
• Explain why one-piece flow is important to manufacturing processes.
• Understand the heijunka technique for load balancing in cells or flow lines.
• Understand how to prevent line defects by using the methods and techniques of poka-yoke.

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Pull Systems

This training module introduces you to the concepts and principles of pull replenishment systems. Pull replenishment systems are one of many processes and techniques that have come to be associated with the development and installation of the Lean Production System. They are an effective way to manage your Production and Inventory Control practices.

Pull Systems provide many advantages over the traditional, MRP based, back-scheduling methods used in manufacturing operations today. The course provides a complete and thorough understanding of what is required to implement a Pull System and exercises to practice your new capabilities.

This course will measure mastery on each of the following performance objectives:

• Define a Pull System.
• Communicate the advantages of a Pull System.
• Determine if a Pull System will work in your environment.
• Identify which data is important to the implementation of a Pull System.
• Design and implement a simple Pull System in your company.

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The Visual Factory

This training module describes the purpose, value, and methods of Visual Controls, or visual signaling and reporting systems used in a manufacturing environment. A plant that relies on Visual Controls to signal abnormal conditions and report process output is called a Visual Factory.

There are many types and kinds of visual signaling systems associated with a Lean Production System. This module discusses these signals and when they can be used. Key topics include: Types of signals, purpose and benefits, barriers, constraints, and implementation issues. The use of visual reporting systems that allow for easily understood, real-time reporting for selected performance parameters, is also explained.

This course will measure mastery on each of the following performance objectives:

• Define a Visual Factory.
• Explain how a visual factory operates differently than a conventional factory.
• Understand the purpose, methods, and values of visual signaling systems used in manufacturing environments.
• Understand the typical analysis and implementation process associated with visual signaling and reporting systems.

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Process Capability and Sustaining Results

This training illustrates the techniques required to establish the capability of a given process. Key topics include the nature of variability and how to measure it, and in the end, predict it. This course also includes examples of process capability studies and how to conduct them. Learners will develop a solid understanding of the techniques required to identify and respond to variation through several examples and hands-on exercises.

One of the goals of a Lean Production System is continuous improvement of the system. There are many techniques and tools that can be used to accomplish this goal. Some of the most powerful sustaining tools that we have at our disposal are the analytic techniques described in this module.

This course will measure mastery on each of the following performance objectives:

• Utilize statistical tools to optimize improvements.
• Describe the nature of variability.
• Explain why statistical tools are needed to optimize improvement efforts.
• Communicate the basics of Statistical Process Control (SPC).
• Define Statistical Process Control.
• Explain the benefits provided by Statistical Process Control.
• Review the measurement system.
• Explain how the measurement system ensures that it is sufficient to accurately highlight and quantify the variation in processes.
• Conduct process capability studies to establish control limits for a process.
• Know where to find additional examples and resources to apply SPC to any process.
• Define the purpose, value and components of performance measurements and a performance measurement system.
• Relate the differences between traditional performance objectives and Lean performance objectives.
• Determine Lean product line objectives and supporting performance measurements.
• Describe how to visually display and communicate Lean performance measurements and link them to Problem Solving Tools.

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Lean Procurement and Supply Chain

This training explains that there are many opportunities inside the factory walls to implement Lean methods and reduce waste. Many more opportunities for eliminating waste, reducing costs, and improving throughput are found with suppliers to the Lean company. The real benefits of a Lean Production System are most evident when the entire supply chain for a product line adopts Lean Manufacturing philosophies.

Key topics include: Understanding historical supplier-producer relationships, improving communications between suppliers and producers, and a discussion of techniques that can be used to drive suppliers towards Lean methods. This module provides examples of the methods used to improve the responsiveness of the entire supply chain for a product line.

This course will measure mastery on each of the following performance objectives:

• Use the techniques and principles of supply chains to support a Lean Production System.
• Be familiar with procurement and supplier requirements to support a Lean Production System.
• Describe the joint responsibilities needed to manage supplier-producer performance and communications.

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Flexible Work Force and Lean Skills Development

This module describes the value and the requirements needed to develop a highly trained workforce, which is a key component of running a Lean Production System. Key topics include: Job task development, key skills, translating business objectives to workforce requirements, functional performance requirements and knowledge transfer evaluations. Employee Lean skills development and cross training requirements are also discussed.

This course will measure mastery on each of the following performance objectives:

• Understand the need and requirements for a flexible, cross-trained workforce.
• Become familiar with standard job task skills associated with Lean Manufacturing.
• Use a cross training matrix to assist in the skills certification process for employees.
• Develop a high-level internal education and training program for the company.

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Lean Manufacturing: The ‘5S’ System

This training describes a ‘5S’ System, its purpose, objectives, and requirements for implementation. A Lean Production System requires organized and clean work spaces. The ‘5S’ System is a perfect candidate for the first Lean Initiative in your Lean Program.

Topics include: definitions, examples, requirements, implementation issues and project plan examples. The learner will participate in active learning exercises to gain an understanding of ‘5S’ methodology.

This course will measure mastery on each of the following performance objectives:

• - Describe the components and requirements for understanding and implementing a ‘5S’ System.
• - Complete an example to show the benefits of a ‘5S’ System.
• - Describe ‘5S’ Tools and how they relate to each ‘S’.

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Injection Molding 101

Injection Molding 101 lays the foundational knowedge base necessary for the success of any injection molding employee.

This package provides employees with broad-based training on the injection molding machine, process, mold, and plastics processing industry. Anyone working with production equipment or handling the material will greatly benefit from this package.

package includes:

• An Introduction to Injection Molding
• Injection Molding Basics
• Understanding Plastics

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Injection Molding 102

Injection Molding 102 builds on the knowledge base established in Injection Molding 101.

This online plastics training package provides a great wealth of information to augment the knowledge of any processor, technician, or die setter.

package includes:

• Understanding Processing Parameters
• Establishing a Scientific Molding Process
• Injection Mold Setup
• Processing For Profit
• Troubleshooting Defects

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Injection Molding 103

Injection Molding 103 provides expert training for anyone looking to take their abilities to the next level.

We recommend participation in our Injection Molding 101 and Injection Molding 102 online training packages prior to participating in these programs.

package includes:

• DECOUPLED MOLDING SM
• Intelligent Molder
• Process Control Systems
• RJG’s eDART™
• The Effects of Shrinkage, Warpage & Part Ejection
• The Effects of Mold Filling, Gating & Weld Lines

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Scientific Molder Package

All injection molders can benefit from RJG’s advanced DECOUPLED MOLDING SM techniques.

Starting from the basics and extending into advanced concepts of DECOUPLED MOLDING SM, this package provides an excellent way to introduce scientific molding training and advance the knowledge any processor in your facility.

Our Scientific Molder package is also a great way to help prepare your employees for Master Molder SM training.

package includes:

• Injection Molding Basics
• Understanding Plastics
• Processing For Profit
• DECOUPLED MOLDING SM

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Injection Molding Maintenance Technician Package

This training package is a great way to teach your maintenance and processing personnel more about advanced maintenance. A good understanding of machine hydraulics is critical to becoming a great processor: it's difficult to troubleshoot instabilities unless you know how the machine manages the hydraulic fluid. Proper injection mold and molding machine maintenance techniques are also covered.

This package makes provides essential training for any technician or maintenance employee.

package includes:

• Injection Mold Maintenance
• Injection Molding Machine Maintenance
• Injection Molding Hydraulics

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Design Engineer Package

No engineer functions at their best without an understanding of the injection molding machine, process, mold, material, product design, and mold design. This extensive grouping of courses helps provide this critical information.

These courses were designed by industry experts and are some of the best training available to design and process engineers.

package includes:

• Injection Molding Basics
• Understanding Plastics
• Understanding Processing Parameters
• Plastic Part Design
• Mold Design and Moldmaking

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Molding Guru Package

With over twenty courses specifically focused on injection molding, this package is designed to make you an expert by giving access to our entire injection molding training library.

package includes:

• An Introduction to Injection Molding
• Injection Molding Basics
• Understanding Plastics
• Understanding Processing Parameters
• Troubleshooting Defects
• Injection Mold Setup
• Establishing a Scientific Molding Process
• Processing For Profit
• Process Control Systems
• The Effects of Mold Filling, Gating & Weld Lines
• The Effects of Shrinkage, Warpage & Part Ejection
• DECOUPLED MOLDING SM
• Math for Molders
• Intelligent Molder
• RJG’s eDART™

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Lean Manufacturing Expert Training Package

This comprehensive package contains 17 distinct courses on Lean Manufacturing Training and covers more than 25 Lean topics from Cell Design to 5S and beyond.

package includes:

• Lean Operations Overview
• The Six Pillars of Lean Production Systems
• Systems Thinking and Problem Solving
• Culture and Change Management
• Lean Performance Measurements
• Continuous Flow and Plant Layout
• Mapping the Value Stream
• Work Flow, Cell Design and Takt Time
• Machine Rightsizing & Change-Over Reduction
• Managing a Lean Program
• Line Balancing, Heijunka & Poka-Yoke
• Pull Systems
• The Visual Factory
• Process Capability and Sustaining Results
• Lean Procurement and Supply Chain
• Flexible Work Force and Lean Skills Development
• Lean Manufacturing: The ‘5S’ System

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