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The following 1-day seminar on “Designing Manufacturing Cells” is being presented at various locations throughout the U

Designing Lean Manufacturing Cells


The following 1-day workshop on “Designing Lean Manufacturing Cells” is being presented at various locations throughout the U.S. and Canada. The workshop can also be structured into 1 1/2 to 2 hour weekly interactive internet sessions conducted over several weeks.  The seminar content is drawn from the experience gained by The Sims Consulting Group, Inc. (SCG) and the seminar’s presenter, Ed Phillips, managing director of SCG.


Ed has performed consulting and training projects for many well-known companies including Alcoa, Apple Computer, AT&T, Canon, Caterpillar, Cummins, Ford Motor Co., General Electric, Gillette, Hewlett-Packard, National Steel & Shipbuilding, Nike, Pratt & Whitney, Seagram, Sears Roebuck, Sony and dozens of small to medium size companies.  He has conducted world-class manufacturing and productivity improvement projects throughout the U.S. and in Canada, India, Malaysia, Mexico, Russia, Singapore, Spain, and Southeast Asia.



Introduction To Lean Manufacturing and Cells

•     Cell characteristics and types

•     The 7 major categories of waste

•     Recommended reading


Product vs. Process Focused Manufacturing

•     What are the major differences?

•     Key characteristics of each approach

•     Pros and cons of cellular manufacturing

•     Positive results and level of importance

•     Focus on the customer


Example Results

•     Typical results (World Class Conversions)

•     WIP reduction

•     Lead time reduction

•     Materials handling improvements

•     Product velocity/throughput


Inventory Carrying Costs

•     High costs associated with carrying excessive inventories

•     Typical inventory turn ratios


Time and Value Added Considerations

•     Problems with traditional approaches

•     Optimizing process flow and value added

•     "Time" based competition


Importance of Batch Size -

Single Piece Flow Example #1

•     Batch size effect on speed and


•     Importance of set-up reduction


Example Problem #2 - Reducing Manufacturing Lead Time from 4 Days to 2 Days


Value Stream and Value Network

  Mapping Considerations


A Step-By-Step Planning Approach

•     Developing the cell success attributes

•     Typical planning steps


Macro (Block) Layouts First!

•       Typical pattern of procedures

•       Data gathering

•       The 3 "A" s of plant layout

•       Analyzing material flows and internal

        materials handling

•       Ranking schemes and relationship diagrams


Example Problem #3 - A “Walk Through” Case Study

•       Development of block layouts with logical cell locations


Kanban Considerations


Team Considerations

•       The 3 "P"s (issues) of cellular manufacturing

•       Cell participation personalities


Production Line / Cell Balances

•     Importance of cycle/takt time and line balancing

•     Precedence diagrams

•     2 methods for determining line station sequence


Example Team Problem #4

•     Establishing a graphical balance


Equipment Reliability Considerations


Example Team Problem #5

•     Team participation Problem

•     Apply learned techniques to determine/ design cellular layouts - team problem


Methods Improvements

•       What to look for - a checklist


The registration fee is US$395 per person. For the dates, times and locations nearest you, please call 1-740-654-1091 or contact us via our website contact us page.

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