Lean Production Control


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Overview

Lean Production Control is the next logical step beyond making value stream improvements for individual product families. This workshop addresses how to implement a Lean production control system, using pull thinking and production levelling to tie together product family flows across the entire facility.

Those who would benefit from attending this workshop include production control, manufacturing management, technical support and purchasing personnel and lean change agents. Organizations that would benefit from this workshop manufacture some standard products made using multi-step processes, and have mastered some basic lean tools and concepts.

This workshop does not cover operational planning (including capacity planning, forecasting, master production scheduling, or material requirements planning) or the material flow within a cell or from a purchased parts supermarket to a cell.

Approach

Through instruction, discussion, an in-class simulation and exercises, this workshop explains how to implement and sustain Lean flow using pull and production levelling, starting with customer demand and working back through finished goods to raw materials.

What You Will Learn

Specific topics include:

  • When to build-to-stock versus build-to-order.
  • Buffering demand using finish goods inventory.
  • Selecting the pacemaker processes.
  • Levelling production.
  • Providing production instructions to the shop floor.
  • Selecting small batch versus one-by-one production.
  • Using replenishment schedule principles versus sequential pull.
  • Using production instruction, parts withdrawal, and signal kanbans.
  • Establishing supermarkets for internal components.
  • Establishing lot sizes for batch processes.
  • Establishing “pitch” intervals for production instructions.
  • Extending Lean production control across the entire facility.

Training Outcomes

This workshop will equip you with all the basic tools needed to design and implement pull and levelled demand systems throughout your facility.

The benefits to achieving a facility-wide Lean production control system include:

  • Manufacturing lead time reduced 20-90 percent.
  • On-time delivery improvement up to 100 percent.
  • Inventory levels optimized.
  • Productivity improved as much as 30 percent.
  • Overtime and expediting reduced

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Training Overview

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WHAT PEOPLE ARE SAYING

SatiStar's Experience Makes The Difference!

  • . . . worked extremely well with the departmental and site managers . . . goal oriented and met the objectives set within the quoted budget and ensured the results were attained for the Company.

  • The guys from SatiStar did more in one week than we were able to do in 6 months.

  • Achieving ISO registration was far less onerous than we thought, our employees really rallied to the cause. The registration effort really brought us closer together as a team, and SatiStar really came through for us when we needed them.

  • We started this process a year ago with Mickey helping us create a spaghetti map of our processes on the whiteboard, and then his team guided us through their streamlining methodology and got us to where we are today. Our processes now look nothing like the spaghetti map – and we’re much more efficient today

  • This projected cycle time reduction of over 80% annual cost savings amounting to over 3% of sales, one-time savings of roughly $10 million, and working capital reduction of roughly $30 million really have us excited!

  • An outstanding success with Motorola’s vendor audit! What made this an exceptional achievement is that it typically takes 4 to 5 attempts to pass this audit. SatiStar’s expertise made it easy to avoid all the extra attempts.