Digital Lean Transformation

Lean Approach and Industry 4.0 Training

₺2,700.00

Content:

History of Lean Production Philosophy, Lean Production Concept
Comparison of Europe and Turkey in Lean Manufacturing Practice
Lean Manufacturing Principles
Waste Definitions and Types in Lean Production
Lean Production Tools and Objectives
Comparison of Classical Production and Lean Production, SWOT Analysis
Lean Transformation Process with Model Factory, Industrial Revolutions, Lean Production Cases
Industry 4.0 Concept, Industry 4.0 and Digitalization Difference
9 Technological Factors Triggering Industry 4.0: Big Data and Analytics, Smart Robots, Simulation, Vertical and Horizontal System Integration, LoT-Internet of Things, Cyber Security, Cloud, Additive Manufacturing, Augmented Reality
Advantages, Disadvantages of Industry 4.0, Destructive Change in Businesses
Turkey’s Position in the Global Value Chain
The Possible Impact of Germany’s Industry 4.0 Transformation on Turkey

Gains:

To be able to explain Lean Manufacturing principles, tools, and objectives.
Ability to categorize wastes in a process.
Developing approaches to prevent waste.
Ability to compare classical production with lean production
Ability to make a SWOT analysis of the current state of a process
To be able to define the concept of Industry 4.0 and 9 Technological Elements that trigger Industry 4.0.
To be able to define the difference between Industry 4.0 and Digitalization.
To be able to interpret the possible effects of Industry 4.0 Transformation on Turkey

Select options

Sold out

Standardization Training

₺1,600.00

Standardization is the creation of procedures that all employees must follow when doing a job. Its most basic method is SOP (standard operating procedures). The purpose of a standard operation procedure is to define the performance of a controlled process.

Content:

Process Management Concept
Components of Process Management
Benefits of Process Management, Process Review
Process Flow Diagram Concept
Methods of Creating Process Flow Diagrams
Concept of Standard, Concept of Standardization
Scope of Standardization
Purpose of Standardization
Function of Standardization
Definition and Purpose of Standard Operating Procedures
Preparation of Standard Operating Procedures
Importance of Standard Operating Procedures,
Examples of Standard Operating Procedures
On the Job Training and SOP Integration

Implementation

Preparing a standard operation procedure

Gains:

Process components;
Process Owners will be able to identify inputs, outputs, resources, documentation needs, goals and metrics.
POs will be able to measure process performance indicators.
POs will be able to understand the workflow symbols and determine their use areas.
POs will be able to create workflow charts of processes.
POs will be able to create the necessary knowledge and know-how for the development and redesigning of processes.
To be able to understand the place and importance of standard operating procedures in enterprises.
Ability to make the necessary preparations to create a standard operating procedure.
Ability to determine the operational steps and basic points of a process.
Ability to create a standard operating procedure for a process.
Ability to perform work to minimize non-standard deviations in processes.
Ability to learn about the quality and efficiency improvements in standardization outputs.
Ability to obtain a standard output with standard ways of doing business, methods.
Ability to get a reference for inspections that can be performed in the process, a basis for improvements.
Ability to prevent Implementation confusion in the process.
Ability to create operations-based processes instead of employee-based processes to support business continuity.

Select options

Sold out

Value Stream Mapping (VSM- Analysis, and Design) Training

₺2,700.00

Value stream mapping (VSM) is a high-level tool that enables lean managers to adopt a systems approach to implementing operational excellence and customer satisfaction. VSM forms the backbone of the continuous improvement roadmap for all processes.

Content:

Work-Study Concept Definition, Benefits, and Purposes of Work-Study
The Concept of Efficiency
Definition of Efficiency and Effectiveness
Work-Study Stages and Techniques
Time Study Form and Usage
Value Stream Mapping Concept and Purpose, Value Added and Non-Value Added Business
Value Stream Mapping Symbols
Value Stream Mapping Steps and Drawing Method
Current State Value Stream Definition, Mapping, and Drawing Steps
Future State Value Stream Mapping Concept
Creating Future State Value Stream Mapping, Benefits of Value Stream Mapping, Examples of Value Stream Maps
Waste Analysis, Identification of Value Added and Non-Value Added Activities
Creating a List of Subjects Open to Improvement, Determining Measurements and Performance Metrics
Time study Implementation
Waste analysis, separation of value-added and non-value-added works and waste.
Value Stream Analysis
VSM current situation, identifying areas open to improvement and creating an action list
Value Stream Design

Implementation:

Time study application
Waste analysis. Separation of value-added and non-value-added works and waste
Value Stream Design
Value Stream Analysis
VSM current situation, identifying the issues that are open to improvement and creating an action list

Gains:

Learning the benefits and importance of work-study for businesses.
To be able to comprehend the difference between the concepts of efficiency and effectiveness.
To be able to comprehend the place and importance of value stream mapping in businesses.
Being able to learn work-study techniques, stages and use study methods.
To be able to handle and evaluate the production processes as a whole.
Seeing waste and its resources, creating a plan for their elimination.
Being able to connect material and information flow
To be able to improve the work as a whole by seeing and understanding the whole of the functional units.
To be able to reveal bottleneck processes by comparing process production times with customer demand.
To be able to make inferences to ensure continuous flow by analyzing the flow paths connected to the product.
Ability to make Layout improvement studies.

Select options

Sold out

Value Stream Mapping 4.0 (VSM 4.0 – Analysis and Design) Training

₺2,700.00

Value stream mapping 4.0 is a tool that shows data flow systems above existing state and lean state value streams, revealing the data system from a systemic point of view and detecting points open to improvement.

Content:

Effects of Digitalization on Social Life, Effects on Factories
New Value Stream Mapping Format vs. Classic Value Stream Mapping Format
New Value Stream Mapping Format; Value Stream Mapping 4.0 and Its Stages
The Effects of Waste Types on Each Other, Waste Detection in Information Flow
Value Stream Mapping Future State 4.0
Determination of Lean Production Tools to Eliminate Value Stream Waste, Value Stream Mapping Example
Consideration of Improvement Opportunities in the Current State Value Stream Map, Future State Value Stream Phases
Value Stream Mapping – Kanban Types, Value Stream Mapping Process Improvements, Future State Value Stream Design
Goals of Digitization Strategy, Integration of Product and Process Information Flow
Future State Value Map 4.0, Value Stream Mapping 4.0 Symbols, Product Stream Improvement, Value Stream Mapping 4.0 Steps
Wastes in Digital Information Flows, Data types, Data flow diagrams
Integration of digital elements, Value stream mapping 4.0 concept and purpose
Introduction of value stream mapping 4.0 symbols, Value stream mapping 4.0 steps, and drawing method
Display of data types on value stream map, Improvement of the data flow system

Implementation:

VSM 4.0 analysis and design

Gains:

To be able to see the effects of digitalization on social life and factories.
Comprehending and comparing new value stream mapping and classical value stream mapping.
Understanding and learning the stages of value stream mapping current state 4.0 and future state 4.0.
To be able to analyze data flow systematics in a process.
Being able to draw the Industry 4.0 value stream map.
Being able to see analog, digital and verbal data streams and detect the breaks between the data streams.
Identifying integration needs between digital elements.
Being able to create a roadmap for Industry 4.0

Select options

Sold out

Total Productive Maintenance (TPM) – OEE Training

₺2,700.00

Content:

Maintenance Concept and History, Maintenance and Cost Relationship, Waste Analysis in the Maintenance Process
TPM Concept and History, Traditional Approach and TPM Approach
Basic Elements of TPM, Implementation Steps of TPM
Responsibilities of Production and Maintenance Departments, Types of Maintenance
Failure Tracking Parameters (MTTR (Mean Time To Retrieve), MTBF (Mean Time Between Failure), MTTF (Mean Time To Failure) rates) Definitions and Calculation Methods
Autonomous Maintenance Steps, Using TPM Error Card
Case Studies, Images and Case Studies, Single Point Lesson, TPM, and JIT Relation
OEE Concept and Calculation Method, Continuous Improvement in OEE
Industry 4.0 in Maintenance, Comparison of Traditional and Smart Care / Advantages of Smart Care

Implementation:

Setting up an autonomous maintenance system
OEE calculation, OEE improvement

Gains:

To be able to define the maintenance cost relationship, to determine the types of maintenance needed in the system.
To be able to make the necessary preparations to create autonomous maintenance forms.
Ability to create autonomous maintenance form and single point lesson form for these points
Ability to calculate MTTR (Mean Time To Retrieve), MTBF (Mean Time Between Failure), MTTF (Mean Time To Failure) rates.
Ability to calculate the availability rate, quality rate, and performance rate parameters, which are the breakdowns of OEE.
Ability to calculate OEE on a business basis, on a machine basis, on an operator basis, on a work order basis, on a shift basis, and determine purposes.
To be able to make progress towards zero downtime and zero error at workstations, to establish a Lean maintenance management system.
Learning the concept of Smart Maintenance and its advantages.

Select options

Sold out

FMEA (Failure Modes and Effects Analysis) Training

₺1,600.00

The FMEA (Failure Modes and Effects Analysis) discipline was developed in aircraft production for the US military in the 1960s. Today it is used in almost every industry as a reliable method for assessing the effects of system, design and process failures.

Duration: 0.5 day

Content:

Definitions of Failure and FMEA
Objectives of FMEA
Why FMEA Is Needed and Its Advantages
Types of FMEA
How to Carry Out an FMEA, Common Difficulties and Expected Benefits
FMEA Steps
Calculating the Risk Priority Number (RPN)
Defining and Implementing Actions
The FMEA Form and Its Use
Sample FMEA Application
When an FMEA Is Completed and When It Is Updated

Module practice: Process FMEA application

Gains:

Understand the place and importance of FMEA in a business
Identify where FMEA should be applied
Run an FMEA study for a process and identify its risks
Design permanent solutions and take action against the identified process risks
Improve the quality results of a process and reduce scrap

Select options

Sold out

Gemba and Kaizen Training

₺1,600.00

Content:

Kaizen Concept, Purpose, Difference Between Kaizen and Innovation
Ways of Improvement, Required Conditions, and Responsibilities for Improvement
Kaizen and PUKO Relationship,
Suggestion System Concept, Kaizen and Suggestion Relationship, Methods of Establishing an Effective Suggestion System,
Gemba Concept, Problem Solving with Gemba, Genchi Genbutsu Concept
A3 Reporting Technique Definition and Purpose, Implementation Steps and Sample Implementation, Poka-Yoke Concept, Implementation Techniques, and Examples
Quality Control Tools Used for Problem Solving;
8D Concept, Stages of 8D Method, Implementation Stages, Sample Implementation
The Concept of Jidoka and Its Historical Development, Aims and Principles, Principles of Practice, Andon Concept and Examples, Correct Andon Design

Implementation:

Suggestion system design exercise, kaizen with 8D method
Andon design exercise, Poka Yoke solution design with A3 technique

Gains:

Understanding the place and importance of Kaizen in businesses and determining the Implementation points.
Identifying the root causes of the problems, preventing the recurrence of errors by applying permanent solutions
Consistent, stable and successful execution of processes, high-level protection of outputs, To be able to apply the 8D method for a problem.
To be able to construct a suggestion system correctly, to be able to solve the problem with Kaizen.
To be able to apply Fishbone analysis, Pareto analysis, 5 Causes analysis for a process. Will be able to do Poka-Yoke work for a process.
To increase the ability of the business to adapt to changes in demand.
By separating the faulty parts at the source and preventing them from going to the next process.
Preventing mistakes without being dependent on people with the Poka-Yoke study.

Select options

Sold out

Workstation Design, Ergonomics, 5S Training

₺1,600.00

Lean workstation design is the design of a process that will provide efficient outputs in accordance with ergonomic rules so that workstations can overcome changes in operating conditions or uncertainties caused by the environment.

Content:

Flexibility Concept, Benefits, Types, Flexible Manufacturing Systems
Classical Approach to Demand Fluctuations
Flexible Manufacturing Systems Against Demand Fluctuations, Flexibility Steps
Flexibility Comparison of Workstation Layout Types
Parameters of Workstation Design; Determination of Material Flow System, Compliance with Ergonomics Rules, Use of 5S Principles, Use of Andon and Other Parameters, Ergonomics Concept
5S Concept and Examples, 5S Implementation Steps

Implementation:

Flexible workstation design
5S Implementation

Gains:

Ability to compare layout types in terms of flexibility in a workstation.
Ability to design workstations that better adapt to demand fluctuations.
Being able to design workstations that can produce with small lot sizes.
Ability to detect and remove obstacles that hinder the movement of workers at a workstation.
Ability to design an ergonomic workstation.
Ability to perform 5S work on a workstation.
Ability to increase inventory turnover.
Ability to reduce stocks of semi-finished products.
Ability to accelerate material transfers and movements.
To be able to create an efficient, visual, and ergonomic workplace.

Select options

Sold out

Yamazumi (Line Balancing) – Milk Run Training

₺1,600.00

Content:

An Overview of Assembly Lines
The Concept of Yamazumi and Its Historical Development
Yamazumi Steps; Segmentation of Jobs, Calculating Takt Time,
Creating a Work Balancing Chart, Improving the Current Situation

Implementation:

Yamazumi graph creation, line balancing Implementation

Gains:

Ability to create Yamazumi graphics and increase the added value per person.
Ability to prevent employees from leaving stations and increase the productive time.
Ability to calculate takt time for a process.
Creating a workload balance between operators, increasing productivity and increasing productivity and production capacity.
It can provide one-piece flow and reduce semi-finished stocks.

Select options

Sold out

Kanban, Heijunka, Milk-Run Training

₺1,600.00

Content:

Kanban Concept, Kanban Pull System and Purpose
Kanban System Implementation Steps
Analysis and Selection of Processes in the Kanban System
Kanban Card Design, Kanban Rules
Kanban Types, Kanban Operation
The Heijunka Concept and Its Historical Development
Mixed Loading Needs in Factories, Mixed Loading Methods
Heijunka Implementation, Planning and Sizing in Kanban System
Comparison of Push and Pull System
Milk Run Concept, Milk Run System Installation Stages

Implementation:

Kanban and Heijunka app
Milk Run calculations and route creation

Gains:

To be able to comprehend the place and importance of Heijunka in businesses.
Ability to give mixed loading capability to a production system.
To be able to use the workforce and machinery in a balanced way.
Developing approaches to increase customer satisfaction and reduce stock and storage costs.
Ability to set up a kanban system correctly.
Ability to create approaches that can prevent delays and remaining orders.
Ability to develop techniques to adapt more easily to changes in production plans.
Ability to make Milk Run calculations and create its route at a workstation.

Select options

-10% Sold out

ERP Supported Production Planning (ERP – MRP II, CRP) Training

Content:

MRP Concept and Purpose, General Structure and Conditions, Product Tree Concept, Product Tree Creation
Capacity Requirements Planning Concept,
Capacity Requirements Planning Process and Stages
Types of Capacity Requirements Planning, Inputs, and Outputs of Capacity Requirements Planning
ERP Concept and History, Main Modules of ERP; Finance, HR, Manufacturing, and Logistics
What are MRP I and MRP II?
The Purpose and Benefits of ERP, Success Ways in ERP Implementation
Dynamo ERP, Dynamo ERP Modules; Accounting-Finance Cost Management,
Stock and Warehouse Management, Production and Planning Management, Purchasing Management, Quality Management, KPI Management

Implementation:

Capacity planning application

Gains:

To be able to comprehend the place and importance of MRP in businesses.
Ability to make the necessary preparations to run MRP. Ability to create a product tree.
Ability to ensure efficient use of resources and identify bottlenecks for a process, Learning the usage areas and advantages of Dinamo ERP.
Developing approaches that will reduce stock amounts and bottlenecks.
Ability to make production planning according to the determined capacities.
Coordinate the necessary functions to achieve the objectives set in a business plan.
To increase efficiency in cash requirement planning.
Ability to organize and improve customer service. To learn the concept of ERP and its history.
Learning the basic Implementations of ERP. Being able to make definitions such as station, stock code, product tree.
Ability to run the MRP module in ERP and automatically open work orders.

Select options

Sold out

Lean Leadership Training