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Strategic Scheduling for Lean

Strategic Scheduling for Lean Manufacturing

In this seminar, participants design a Lean scheduling system for their own plant.  They will integrate the six basic scheduling methods into a practical strategy for Lean Manufacturing. This is a unique offering that covers fundamental topics not found in the usual kanban or scheduling courses. 

Program Summary

Format Onsite Workshop Oline Who Should Attend?
Time 2-Day 2-4 Wks Managers
Engineers
Materials Managers
Schedulers
Production Supervisors
Cost $5700 (Includes Travel) $4700
Participants 5-40 5-20
Next Step Call us at 816-931-1414

Participants Will Learn...

Some Basics

  • Lean Manufacturing and what it requires from scheduling.

  • How to clarify conflicting scheduling objectives.

  • To measure and track scheduling performance.

Inventory, Capacity, & Backlog

  • The role of inventory in Lean.

  • How scheduling can reduce the financial demands that inventory makes .

  • Why excess capacity can be profitable.

  • How to determine utilization goals.

  • Why capacity decisions are strategic and NOT financial.

  • Make-To-Stock, Make-To-Order, or Assemble-To-Order.

Forecasting

  • The limitations of forecasting and how to overcome them.

  • Guarding against forecasting surprises.

The Science Behind Scheduling

  • System Dynamics, Chaos & feedback.

  • Why systems go berserk from chaos, oscillation and instability.

  • Using Theory of Constraints.

Rationalized Lot Sizing

  • How to calculate the best Lot Sizes. 

  • Why small lots ease planning & reduce inventory.

Production Scheduling Methods

  • Six basic methods & where they apply:

Broadcast

Kanban

Period Batch Control

Direct Link

Re-Order Point (ROP)

MRP/ERP

  • How Kanban simplifies MRP and improves performance.

  • Simplify, streamline & integrate MRP.

Developing Your Strategy

  • How to select the optimum method for each process and each product group.

  • About integrating various methods into a comprehensive scheduling strategy.

  • The implementation action plan.

Program Outline

1. Introduction

What Is Scheduling?

Identify Your Objectives

How To Measure Performance

2. Forecasting

The Components of A Forecast

Forecasting Methods

How Good Is Your Forecast?

 3. Inventory, Capacity & Backlog

 Inventory Record Accuracy

The Role of Inventory

Capacity

How To Measure & Define Capacity

What Capacity Should You Provide?

What Is Backlog?

Backlog, Inventory, & Capacity

Make-To-Stock, Make-To-Order, or Assemble-To-Order?

 4. Lot Sizing

What Lot Size Should You make?

How Lot Size Affects Scheduling & Inventory

5. Theory of Constraints (TOC)

Marching Exercise

The Corrupting Effects of Variability 

How To Apply TOC

6. The Dynamics of Production Systems

The Beer Game: Instability & Chaos

 7. Six Production Control Methods

What Is Kanban?

Exercise: Operating A Kanban System

How To Design A Kanban System

Re-Order Point (ROP, Min-Max)

Materials Resource Planning (MRP/ERP)

How Does MRP/ERP Work?

The Hazards of MRP/ERP

How To Make MRP More Effective

Integrating MRP/ERP With Other Methods

 8. Putting It Together

Developing Your Strategy

The Hierarchy of Methods


Backlog, Inventory & Capacity are interchangeable.

Economic Lot Sizing 

Seasonality

■ ■ ■ ■ ■ ■ ■

Value Stream & Process Mapping

The Strategos Guide To Value Stream and Process Mapping goes  beyond symbols and arrows. In over 163 pages it tells the reader how to do it and what to do with it.

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