Free training in lean manufacturing

On 8 November 2012 as part of the project "Development of cooperation and increase of competences of the CNNOMATECH Cluster in order to strengthen innovation of Lower Silesia" co-financed from the budget of the Lower Silesia Voivodeship, training took place in the field of thin production of the so-called Lean Manufacturing concept.
The training programme included 2 parts:
1. Theoretical
2. Practical

The theoretical part presents an introduction to the strategy for managing production systems, i.e.
1. Production system - basic concepts
Basic information about the production system (What is the system, process, product, production system, input and output description)

2. Pushing strategy
the history of manufacturing management in the pill (prehistory - 18th century) - when in the history of humanity there were breakthroughs in manufacturing, and later in manufacturing management two fundamental inventions: division of labor - spare parts (i.e. the worker does only part of the work instead of performing the product in its entirety by passing on the result to the next employee - and the production of many almost identical parts which can be assembled interchangeably in the final product) industrial revolution (Watta steam machine and later combustion engine) Ford and the problem of mass production (genial Ford falls on the idea of the production line which causes the American market to fall asleep with its Ford T)

3. Suction strategy
Taichi Ohno - Japanese engineer, who after World War II learns how to produce from Americans. He practices with Ford and comes up with Just in Time JiT
JiT - continuous product flow through the production line and delivery of materials on the line when needed,

and the essence of Lean Manufacturing:
a) Waste - most operations carried out during the production process, which do not add value to the product (i.e. the product after performing such operation is no longer worth more to the customer, and the cost of the operation has been incurred - in large simplification these are storage, transport, quality control, waiting for processing, etc.). Taichi Ohno invented seven kinds of waste...

b) Kaizen - a philosophy of self-improvement within the production system, covering both employees and the entire organization

c) Value Stream Mapping - the method of mapping the value stream - the basic tool for implementing the philosophy of "Lean", or slimming the production system - is to create a map of the state of the current process, in order to determine where we are from, and then a map of the target state, on which any planned improvements are made, which can be achieved by using other instruments of Lean philosophy (i.e. SMED, Kanban, 5S, TPM, etc.)

d) Kanban - a production control system consisting of sending information about the need to supplement the material in the opposite direction to its movement (e.g. stand B produces in the final warehouse when it gets information about the decrease in the quantity of the product in the warehouse - because the customer bought - uses the material from its entrance, which is the reason for sending the signal to station A, which produces the materials. In turn, position A uses its materials which makes it necessary to replenish them from the input warehouse, etc.)

e) 5S - tool for reorganization and optimization of the manufacturing process at a given workplace

f) SMED - The technique for the optimization of the machinery's refurbishment - is based on the division of the work on the machine's refurbishment into two types - external, which can be done when the machine works and internal, which can only be done after the machine has stopped

g) TPM - a system of management of manufacturing resources aimed at preventing uncontrolled job losses

In addition, workshops were conducted, comparing two strategies (sucking and pushing) on the example of a simulation experiment.