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LEAN ENTERPRISE WORKSHOP SERIES

 Series of Half Day Workshops

 APICS Lean Enterprise Workshop Series Overview

The APICS Lean Enterprise Workshop Series is an in-depth seven (4 hour) workshop study of the lean principles that companies need in order to meet the demand of today’s manufacturing and service environments. In the workshop series, participants will follow Murphy’s Toys, a fictitious company, through their lean transformation and learn principles and methodologies along the way. The series offers numerous interactive activities for participants to maximise learning and retention, master lean terminology, and create a lean implementation plan.

Workshop 1 – The Lean Enterprise: Introduction

This workshop offers an introduction to lean from the perspective of a manager at Murphy’s Toys, which is a fictitious company studied throughout the series. Participants will learn about the basic philosophy of lean, the steps to a lean transformation and the House of Toyota framework as well as how to determine product families, correct waste and quantitatively assess an organisation’s lean status.

Workshop 2 – The Lean Enterprise: Lean Culture

Lean is a people and culture driven process. In this workshop, participants will explore the effects of a lean implementation on employees, brainstorm ideas for implementing change management at Murphy’s Toys and learn the importance and stages of teams in lean environments. An important lean tool, the kaizen, or team-oriented continuous improvement event, will be introduced and participants will study a problem at Murphy’s Toys, completing a kaizen report. Murphy’s Toys will choose the product family to use in the pilot of their lean implementation.

Workshop 3 – The Lean Enterprise: Value Stream Mapping

Value stream mapping is a valuable tool for viewing processes and determining potential areas of improvement. Using standard value-stream mapping icons, participants will draw a current state value stream map of the injection moulded plastic toy production line at Murphy’s Toys. Participants will then learn what makes a value stream lean, after which they will apply this new knowledge as they develop a future state map.

Workshop 4 – The Lean Enterprise: Stability and Process Improvement

In this workshop, participants will learn how to achieve demand stability and improve processes. Concepts covered include load leveling, mixed-model production, buffering, causes of variation, standard work, total productive maintenance and an introduction to six sigma. Participants will explore methods to reduce setup time through activities.

Workshop 5 – The Lean Enterprise: Just-in-Time

Now that Murphy’s Toys has stabalised its processes, it needs to focus on scheduling production to meet customer demand. This workshop covers determining customer demand, line balancing, continuous flow, implementing pull, scheduling with heijunka and the use of kanbans. Through a hands-on activity, participants will explore the use of a heijunka system to meet customer demand.

Workshop 6 – The Lean Enterprise: Measuring

Traditional measurements are not working well for Murphy’s Toys as they transform to a lean enterprise. In this workshop, participants will compare and contrast traditional to lean measurements and their resulting behaviours. A review of lean accounting includes such topics as standard cost vs, value stream profit and loss statements, the financial impact of lean improvements, target costing and lean decision making. Participants will examine the lean metrics that Murphy’s Toys can use.

Workshop 7 – The Lean Enterprise: Sustaining

Now that Murphy’s Toys has undergone a lean transformation, it must implement long term changes to sustain the gains made. These include implementing lean design, analysing failures and ensuring on-going quality control and continuous improvement. In this workshop, participants will perform a failure mode and effects analysis (FMEA), analyse a problem using the six sigma DMAIC tool and create a lean implementation plan to take back to their organisations.

Murphy’s Toys

Murphy’s Toys is a fictitious company created for the APICS Lean Enterprise Workshop Series as an on-going case study for the series. At Murphy’s Toys, complaints are high, quality is low and demand is building for toys. Each workshop in the series illustrates one step in the story of Murphy’s lean transformation. Participants will learn lean principles through activities that include studying Murphy’s corporate data, mapping their value streams, levelling their production and measuring their success.

Half day Workshops

These six 4hr. workshops cover the whole cocept of Constraints Management