Lean Tools for Continuous Flow and Pull Systems: 5S, Kanban, Standard Work, Visual Controls, and Mistake Proofing

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This 2-Day course will teach participants how to implement continuous flow and pull systems.  It includes topics such as understanding takt time, physical layout, analyzing standard work and creating standard work charts, line balancing, load-leveling, inventory management, and the mechanics of kanban and pull systems. It also includes the application of 5S, Visual Controls, and Mistake Proofing tools to these systems.   Participants will work through case examples and simulations. The course also includes a factory simulation in which participants will build widgets using traditional mass production methods; they will then utilze lean one-piece flow techniques and compare results.



Lean Tools for Continuous Flow and Pull Systems: 5S, Kanban, Standard Work, Visual Controls, and Mistake Proofing (2 Days)

Next Session: October 2017 - Dates TBD

Time: 8:30am - 4:30pm

Location: Doubletree Club Hotel Orange County Airport, 7 Hutton Centre Drive, Santa Ana, CA

Instructor: Darren Dolcemascolo

Price: $895 (early registration) / $995 (regular registration)

Price includes books, materials, and lunch at instructor-led sessions.

Registration Available soon


If you would like to bring this workshop on-site to your facility, contact us.
Lean Tools for Continuous Flow and Pull Systems: 5S, Kanban, Standard Work, Visual Controls, and Mistake Proofing Outline
  • Lean Flow and Pull Systems
  • Benefits of continuous or single-piece flow
  • Identifying and selecting product families
  • Calculating takt time
  • Creating Standardized Work
  • Identifying and recording work steps
  • Team Exercise
  • Operator Balancing and Layout Guidelines
  • 5S Visual Workplace
  • Mistake Proofing
  • Equipment Requirements
  • Material Management / Kanban Replenishment
  • Team Exercise
  • Scheduling/Leveling Production
  • One Piece Flow Simulation Team Activity
  • Finished Goods Warehouses v. Make-to-Order Operations
  • Calculating Inventory Quantities for Kanban Replenishment
  • Team Exercise
  • Types of Kanban
  • How to schedule a value stream
  • How to level production (heijunka)
  • How to convey demand to the pacemaker to create pull
  • How to Manage upstream Information and Material Flow Utilzing Kanban
  • How to expand your production control system
  • Sustaining and Improving