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About the LEARN program

LEARN: COURSES AND CERTIFICATION

Our online courses were originally designed for a Fortune 100 client. They have been thoroughly reviewed to include the necessary in-depth information that you will need in order to design world-class production lines and material delivery systems. Each course will walk you through the complete series of steps, from research and data gathering, all the way through to deployment.

Mixed Model Line Design Course and Certification

Mixed Model Line Design is the step-by-step methodology for designing high-mix production lines or value streams. The result is a production line that can manufacture a large number of different products and options, with high efficiency and quality.

The tools of Mixed Model Line Design allow the design of lines that can handle inevitable changes in mix and volume, without degrading throughput or productivity. And they avoid the need for batching models, and for extensive and costly line changeovers.

How do you know if the line is performing as expected? Is that slow down normal? Getting educated in Mixed Model line design will enable you to “read” the line so you know how it is performing.

Mixing products has a host of advantages including better lead times, increased flexibility, more efficient use of floor space, and leveled product volumes.

A Process Flow Diagram shows the relationship between your processes and the flow (or sequence) necessary to make one unit of a specific product.

One Process Flow Diagram does not provide enough information to make well-informed decisions on the whole line, so you must find a way to extract applicable information.

Takt Time is the line’s formulated production rate. This rate is calculated and is an important design parameter for the line.

In this lesson we’ll cover some of the difficulties you must overcome to calculate an accurate Takt Time, including how to account for many factors that influence Takt such as changes in Effective Minutes, Rework, Scrap, Options, and Quantity consumed.

Standard work is a foundational element of Lean. In this lesson, we will discuss the benefits of Standard work, how to use Standard Work, and why it is important to use graphics in your Standard Work definitions.

Understand how to use the Resource Calculation Formula, and learn how to interpret and apply the results of your Resource Calculations.

In this lesson, you will learn how to calculate the necessary number of workstations on your line and how to determine the distribution of work between those workstations.

In-Process Kanbans (IPKs) are a necessary component of many mixed model production lines. In this lesson we will introduce the benefits and application of IPKs, as well as the best methods for calculating the optimum number of IPKs between your workstations.

Learn about the six line balancing tools, how to use them, when to use them, and the incredible benefits that come with a well balanced line.

Every line designer has to consider how machine processes will impact his or her line. In this lesson, you will learn about the different types of machines, their strengths and weaknesses, and how to integrate machines with IPKs and the balancing tools.

Every mixed model production line has to deal with changeovers, but you don’t have to allow those changeovers ruin your design. This lesson is all about strategies to minimize, as much as possible, the negative impact of changeovers on your line design.

Before jumping straight into CAD, it is important to first create a conceptual design. In this lesson you will learn why conceptual designs are useful, how to create them, and which inputs go into a conceptual line design.

When is Simulation Modeling necessary? What data goes into a successful model? How do you get that data? And, when the model is completed, how do you analyze those results?

This lesson teaches you the steps that go into creating your Final Layout, as well as the departments that should be involved.

Once you CAD drawing is complete, how do you take that drawing and turn it into a live production line?

Mixed Model Material Management Course

By the end of this course, you will understand how to design a material delivery system that supports the management of a large number of different products, options, and items, with high efficiency and quality. We would go so far as to claim that your material delivery system, following our methodology, will essentially shortage-proof your production lines.

The tools of Mixed Model Material Flow can handle inevitable changes in mix and volume, without delaying or stopping the line. And they can do so efficiently, without overstaffing or wasteful material delivery activity.

Develop a deep understanding of the optimum material delivery workflow and strategy.

The surprising source of modern material flow systems.

Every individual item that will be managed, both purchased and manufactured, will be documented in detail in the PFEP database.

Your job as the designer of a material delivery system is to know which tool to use. Kanban is a general term that refers to a variety of different pull signals, which will be examined one-by-one.

Kanban means “signal”, and the supermarket strategy for managing inventory and overcoming imbalances is an essential element of a Lean material management strategy.

Kanban is not the only signaling method that will be used, and this lesson reviews to options available to a Material Flow designer.

One of the goals of Lean Material Flow is to balance material coverage (no shortages) with high inventory turns. In this lesson you will calculate optimum inventory levels for a variety of different items.

Material presentation is an integral part of optimum workstation design. In this lesson you will review basic objectives and examples, as well as look at some provocative new ways to deliver and present materials to an operator.

Material presentation is an integral part of optimum workstation design. In this lesson you will review basic objectives and examples, as well as look at some provocative new ways to deliver and present materials to an operator.

Material presentation is an integral part of optimum workstation design. In this lesson you will review basic objectives and examples, as well as look at some provocative new ways to deliver and present materials to an operator.

You will choose from a variety of Material Conveyance methods, from hand delivery to Automated Guidance Vehicles (AGVs).

The philosophy of “frequent trips and light loads” will be accomplished through the design of your delivery routes. The establishment of Standard Work for material delivery is also applied in this step.

The Lean Material Flow strategy puts a strong emphasis on container standardization. The integration of containerization strategies with internal Kanban systems and outside supplies will be understood.

Material Flow designers use a “roadmap” or checklist, for consistency and completeness. In this lesson you will learn the 10 Key Design Principles.

A Lean Material Flow system will continue to use computer systems for planning and inventory control, and high inventory accuracy is a must.

The material delivery system needs continuous vigilance and management. In this important lesson we will review the methods and practices needed to ensure that your system is on a path of continual improvement.