LEAN Enterprise
TWI - Training Within Industry
TWI consists of three standardized programs that teach the essential skills needed by all supervisors and team leaders, regardless of their industry. These programs are: Skill in Instruction, Skill in Improving Methods, and Skill in Leading People.
TWI "J" Programs
Job Instruction Training (JI) Teaches supervisors how to quickly train employees to do the job correctly, safely, and conscientiously.
Job Methods Training (JM) Teaches supervisors how to produce greater quantities of quality products in less time by making the best use of the people, machines, and materials now available.
Job Relations Training (JR) Teaches supervisors how to build positive employee relations, increase cooperation and motivation, and effectively resolve conflicts as they arise.
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Equipment / Process Review (EPR)
NEPIRC will spend a few days on your shop floor checking out the efficiency of the equipment and manufacturing processes used in your production process. Then their experts will recommend changes to maximize the effectiveness of each component. The result: Your company will enjoy increased capacity, less downtime and improved profits.
Plant Layout
We understand that small manufacturers like you often expand over the years according to available space and current orders. You may look back on your facility and think, "OMIGOD! What happened?" We also understand how much an effective plant layout benefits your flow, your capacity, and therefore--the bottom line. If you're in this situation or putting up a brand new facility, we can help you design the flow that works best for you.
Lean 101: Principles of Lean Manufacturing Training
This 8-hour course is a mix of classroom and live simulation. Participants gain an understanding of the 8 wastes in manufacturing and learn how to apply standard work, visual controls, set-up reduction, batch size reduction, point of use storage, quality at the source and pull systems to eliminate these wastes. No previous experience with lean is required but experienced staff will benefit from this event.
Value-Stream Mapping
Whether you have made the decision to adopt lean manufacturing or are still not sure of its strategic fit, value stream mapping is the place to start! Defining value versus non-value and mapping the activity within your organization is the most critical step towards becoming lean. Manufacturers learn to see the organization as a value stream by creating current and future-state “maps” of the organization that are the basis for all lean implementations and define the work that lies ahead.
Set-Up Reduction
Setup or changeover is the preparation of a production line or piece of equipment for a different process or product. Setups often take hours, even days to complete (all of which is 100% non-value added time). Based on the Single Minute Exchange of Dies philosophy, documented by Shigeo Shingo in The SMED System, this implementation involves an analysis of an actual changeover process and set-up reduction in a team environment. Typical results range from 50-75% reduction in set-up time after the first iteration, providing additional capacity and driving up productivity.
Lean Manufacturing Blitz
The key to becoming lean is an environment of continuous improvements. For that reason, all lean implementations start and end with training. After learning about underlying concepts and principles, NEPIRC facilitates practical application on the shop floor and follows-up with a presentation of results and lessons learned.
NEPIRC supports manufacturers with an extensive array of process improvement programs that follow this train-do philosophy. Our team consists of highly qualified lean implementers experienced in a wide range of manufacturing processes, and the programs and implementation tools are flexible and adaptive to specific client needs.
Total Productive Maintenance (TPM)
Total Productive Maintenance (TPM) goes far beyond traditional maintenance boundaries to attack equipment related waste, reduce equipment downtime and improve overall equipment efficiency. Training establishes the five components of TPM which cover maintenance prevention, preventive maintenance and improvement-related maintenance. The business impact of TPM is measured in shorter lead times, higher product quality, lower inventory and improved on time deliveries.
Visual Controls
This is generally the first step towards becoming lean. Building on Toyota’s original 5S recipe, it is much more than simple industrial housekeeping. A 5S+ 1 visual workplace is a self-explaining, self-ordering, self-regulating and self-improving work area where what is supposed to happen does happen every time, day or night. Manufacturers discover the concepts that drive and sustain this process and apply them to the shop floor. Creating order and visual controls is essential to any successful lean project and is applied within every lean implementation program.
Cellular Design
Creating process flow on the shop floor requires balancing manufacturing operations against standardized work and customer demand. Manufacturers learn to reduce lead times, minimize work in process, optimize floor space usage, and improve productivity through NEPIRC’s 5-step process for designing and implementing work cells. This process applies to both assembly and machining applications. Implementation presupposes the client has defined and mapped the value stream and undertaken a 5S+1 visual control program.
Pull Systems
Throw away those 30-day build forecasts! Manufacturers becoming lean control their shop floor inventory and production schedules by implementing pull systems. This program facilitates the design and implementation of a visually driven, employee controlled material replenishment system. Manufacturers learn how to implement repetitive and non-repetitive pull systems, set up point-of-use material storage, interface with planning systems and balance lot sizes with capacity, not economic order quantity. The full potential of a pull system is realized only when implemented in conjunction with cellular design.
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