UNIT 1. PRODUCTION AND LEAN MANUFACTURING

1. The business environment
2. Differences between the concepts of productivity, efficiency and effectiveness
3. Production planning
4. Process-based business management system
5. Process and activity map: selection and sequencing
6. Configuration of manufacturing systems
7. Design of flexible manufacturing cells: plant layout
8. The manufacturing plan : study of the work method
9. Internal customer and external customer
10. UNE-ISO and ISO on Lean and Sigma

TEACHING UNIT 2. VISUAL MANAGEMENT AND ITS TOOLS, ANDON, KAMISHIBAI, A3 REPORT AND OPL

1. Visual management and control
2. Andon system
3. Kamishibai or green red task board
4. Problem Solving Report A
5. OPL One Point Lesson

TEACHING UNIT 3. JUST IN TIME AND PRODUCTION LEVELING

1. Just in Time (JIT)
2. JIT Principle of Takt Time: Takt Time
3. Stacked Bar Diagram (Yamazumi)
4. Demand Leveling: Heijunka Technique

TEACHING UNIT 4. VSM TECHNIQUE ADDED VALUE MAPPING AND SMED

1. Process Mapping and Reengineering: Value Stream Mapping (VSM)
2. Value Stream Mapping (VSM)
3. SMED: Rapid Machine Changeover
4. Stages of the SMED Method
5. Application Techniques for SMED Analysis and Implementation Examples

TEACHING UNIT 5. JUST IN TIME FLOW PRINCIPLE AND TOOLS: OPF, BALANCING, GROUPING AND LAY OUT

1. Lean manufacturing VS cellular manufacturing
2. Plant layout under Lean configuration
3. Flow Principle VS traditional batch production
4. One Piece Flow
5. Balancing operations
6. Technology clustering or group technology
7. Lay out of U-shaped lines: chaku-chaku

UNIT DIDACTIC 6. PRINCIPLE OF PULL, JUST IN TIME AND TOOLS, KANBAN, SUPERMARKETS, FIFO AND MILK ROUND

1. PULL vs PUSH production control systems
2. Kanban cards: characteristics, types and calculation
3. Lean supermarkets and dynamic FIFO shelves
4. Milk Round logistics circuits

UNIT DIDACTIC 7. TOTAL PRODUCTIVE MAINTENANCE (TPM): PILLARS AND KPI INDICATORS

1. Emergence of the concept of TPM Maintenance typologies
2. Definition and objectives of Total Productive Maintenance
3. The six major equipment losses
4. Basic pillars of TPM
5. Autonomous maintenance
6. Performance indicators in maintenance: reliability, maintainability and availability (practical calculation)
7. Performance indicators in production: OEE, TEEP and OTD (practical calculation)

UNIT DIDACTIC 8. TOTAL QUALITY MANAGEMENT AND KAIZEN.

1. Total Quality Management TQM Quality assurance systems
2. Continuous improvement and total quality
3. Quality control in design phase
4. Quality control in manufacturing process phase : self-control and fine-tuning release
5. Final quality control stage
6. Statistical control of the SPC process
7. Descriptive statistics: Calculation of mean and standard deviation
8. Use of control/trend charts: upper limit LCS and lower limit LCI
9. Process capability KPI calculation Cp and Cpk
10. Quality indicators: defects per million, first time quality and normal performance
11. Traceability
12. Kaizen
13. Suggestion system
14. Short interval management (SQM)

UNIT DIDACTIC 9. THE SIX SIGMA UNE-ISO 13053 METHODOLOGY

1. The idea of an acceptable error rate
2. History of Six Sigma
3. Definition of Six Sigma
4. Six Sigma VS Total Quality VS Quality Assurance
5. DMAIC Phases for Six Sigma: Definition, Measurement, Analysis, Improvement and Control
6. Six Sigma project selection
7. Recommendations, factors and barriers for success in a Sigma project according to UNE-ISO 13053-1
8. Motorola Stages for process performance improvement with Six Sigma
9. Six Sigma Level Calculation Application Examples