Waste elimination and 7 IE tools

Why should waste be eliminated in production?

Producing many defective products causes great damage to the company.
Overproduction gives rise to excessive costs for warehousing, storage costs, manpower costs, equipment costs, etc
Storage excessive and for a long time causes businesses to not only sink into unproductive assets, but also lead to other costs such as warehous renting, product storage or expenses due to damage, etc
Errors in paperwork, providing false information about products, delayed delivery, manufacturing the incorrect specifications, excessive use of materials or generating unnecessary scrap, etc cause a lot of waste for the business
The business knows that there is a lot of waste in production, but the application of waste elimination tools still faces many difficulties.

The course “Waste elimination and 7 IE tools” will help businesses find out problems with improved opportunities to reduce ineffective activities in their own factories and companies.

COURSE OVERVIEW

Name of the course: Waste elimination and 7 IE tools

Object: Employees, workers, interns

Training time: 2 – 3 days (designed as customer’s requirements)

Language: Vietnamese

Lecturers: Vietnamese

Forms of training: Inhouse or Public workshop

Training methods: Lecture presentation, discussion, and practice are organized in the classroom

PURPOSE OF COURSE

Correctly identify 7 types of workplace waste
Apply each IE tool to reduce, eliminate 7 wastes.
Continuous improvement for a lean and highly productive workplace.
Build improvement systems throughout the organization.

TRAINING CONTENT IN THE COURSE

Topic 1: Muri-Muda-Mura and 8 types of waste

What is Muri-Mura-Muda?
What are the 8 types of waste? (Definition, identification)
Practice 1: Identify situational waste

Topic 2: Workflow analysis

What is the San-Gen-Shugi methodology? (Genba ,Genbutsu & Genjitsu- Principle of three realities)
Determine the actual time of the stages in the production line, or of the working steps in the workflow
Create a flow chart of work and identify waste
Practice 2: Process chain analysis and situational waste identification

Topic 3: Table of standard work coordination

What is Tact time? What is cycle time?
What is chart of standard work coordination?
How to chart a standard work coordination and identifying waste
Practice 3: Chart a standard work coordination and identify situational waste

Topic 4: The analysis chart of SIMO coordinated manipulation

What is a SIMO chart?
How to make a SIMO chart
On-line work, off-line work, adjustment work
Practice 4: SIMO charting and waste identification

Topic 5: The analytical method of two-handed manipulation

What is the analysis of two-handed manipulation?
Analytical method of two-handed manipulation and waste identification
Practice 5: Analyzing two-handed manipulation, identifying waste

Topic 6: Analysis methods of Therbligs movements

What is Therblig Analysis?
18 types of movements of Therblig analysis
Practice 6: Analyzing Therblig and identifying waste

Topic 7: Analysis of the transportation process, From-To

Analysis of the transportation process and what is From-To?
How to chart to analyse the transportation process
How to make a chart From – To
Practice 7: How to chart transportation process, from-to and identify waste

Topic 8: Solutions of waste elimination and minimization

ECRS solution (Eliminate – Combine – Reorder – Simplify)
The principle of economic manipulation
Karakuri method
The principle of the transportation process
Pokayoke
Practice 8: Determine the solutions of eliminating and minimizing situational waste

Course review, action plan and certification