Production Workshop Manager

Identifying production improvement opportunities

• Identifying market developments and customer expectations; tracking production system developments through to Lean.
• Challenging flows and identifying the implications for workshop performance.
• Integrating problem-solving tools into the organisation: PDCA and 8D.

Exercise: Lean game

Improving operational performance

• Diagnosing your unit using MIFA.
• Understanding basic tools for continual performance improvement:
  • The 5 Whys, 5W1H (QQOQCP), QRQC and others.
  • The diabolo effect and the logic of addressing bottlenecks in descending order.
• Virtual alignment.
• Workshop material-handling systems.
• Operator positions, fixed assignments and work sequences at workstations.
• Individual monitoring.

Improving managerial performance

• Adapting behaviour across hierarchical levels to professional situations: the AIP approach.
• Managing conflicts and making arbitration decisions.
• Addressing resistance to change.
• Seeking team autonomy and motivation:
  • Forward-looking skills management.
  • The successful delegation process.
• Diagnostic tools: supervision study and Tour Study.

Production planning, scheduling and release

• Sales forecasts.
• Material Requirements Planning (MRP/CBN) and the Master Production Schedule (MPS/PDP).
• Make-to-order and make-to-stock production orders; Kanban concepts.
• Optimising batch sizes.
• Changeover and cleaning times; SMED concepts.
• Planning shutdowns and other unavailability.
• Optimising the production monitoring board: planning, scheduling, procurement, receipt, release and stocking.
• Integration approaches for bills of materials and backflushing.

Workforce planning and monitoring

• The qualitative and quantitative multi-skills matrix.
• The staff allocation board.
• The schedule for classroom training or paired training in production.
• Personnel files.

Service levels and inventory management

• Detailed objectives and seasonality for finished-goods and supply stocks.
• Qualitative and quantitative inventory monitoring and control.
• Scrap: decisions, valuation and reduction.

Managing workshop results

• All performance indicators.
• Recording frequency and responsibilities.
• Monitoring financial performance: working capital requirements and inventory expressed through average daily consumption (CMJ), from stockouts to obsolescence.
• Daily management of corrective actions and improvement plans.

Case study: building an individual improvement plan

Course benefits:

Understanding the approach through a dedicated group game, concrete examples and films of companies that have implemented Lean.
Learning the methodology and basic Lean tools for rapid audits and rapid on-the-job operator training. Redesigning workshop management organisation and building a pilot project.