IMTMA Training Centre

Certified Lean Practitioner- Achieving MAXimum from MINimum

Date : 7 to 16 December, 2021

Time : 1340 Hrs to 1730 Hrs

Introduction

Lean is a systematic methodology with a focus on the Customer to separate Value-Added and Non-Value Added Activities ( Waste ), and then reduce and eliminate Waste in all processes.

For a practitioner, it is a manufacturing system that allows minimal use of resources to produce defect free products in the shortest possible time with least amount of left over. In short ‘Maximum with Minimum’.

Lean is a system that drives organization toward zero waste. It is called Lean because Lean system

  • Needs less human effort to design, make and service products.
  • Requires less investment for a given amount of production capacity.
  • Creates products with fewer delivered defects and fewer in-process turn-backs.
  • Utilizes fewer suppliers with higher skills.
  • Goes from concept-to-launch, order-to-delivery and problem-to-repair in less time with less human effort.
  • Could cost-effectively produce products in lower volume with wider variety to sustain pricing in the market while growing share.
  • Needs less inventory at every step from order to delivery and in the service system.

A Lean Manufacturing practicing organization will significantly improve its business and operational performance like Throughput, Quality, Delivery, Cost, Safety, Inventory Turns, Profitability, ROI and Cash Flow. 

It is all the more imperative today when most of the organizations are concerned about Cost, Profitability and Cash Flow.

Due to the multiple benefits and current pressing requirements, IMTMA is organizing a 20 Hrs Online Certification programme on ‘Lean Practitioner’

 

 

Focus Areas



  • Overview of Lean & 4Ps ( Philosophy ) and 14 Principles of Lean
  • Birth of Toyota Production System and House of Lean & 7 Lean Manufacturing guidelines
  • 5S – World Class Workplace Organization
  • Good Safety Management Practices, Hazard Identification and Job Safety analysis
  • Visual Management, Visual Factory and Identification and reduction, elimination of various process wastes – Muda, Muri, Mura, Standing in a Circle, Waste walk.
  • Kaizen – introduction and institutionalization / Kaizen event / Workshop
  • OEE – Overall Equipment Effectiveness, SMED – Set up time reduction, PQ-PR Analysis
  • Value Stream Map ( VSM )
  • Difference between PUSH & PULL system & Various layout options – pros and cons
  • Some Motion Analysis: Man-Machine Chart, SIMO Chart, Spagetti Diagram.
  • Skill Matrix, Multi-skill
  • Standard Operations to improve FLOW – Takt Time, Time Observation sheet, Process Capacity sheet, Standard Work Combination sheet, Yamazumi Chart, Line Balancing ideas, Standard WIP, Standard work.
  • Understanding KANBAN PULL System, establish 2 Bin KANBAN system
  • Basic Problem Solving Tools
  • Quality Circle, Gemba huddle, Daily Work Management
  • Important KPIs to drive Lean in Operations
  • Case studies & Roadmap for Implementation

Key Take Aways



After undergoing the programme, the participants will be able to –

  • Gain an insight into Lean Manufacturing ( Toyota Production System ) system
  • Understand how adoption of Lean system can significantly improve Operational efficiency
  • Prepare a roadmap to create Lean Value Stream
  • Learn various Lean Tools and Techniques to be a basic expert
  • Plan a journey toward JIT and Jidoka – 2 key objectives of Lean Mfg
  • Implement various Lean tools and practices to realize significant productivity gains

Training Methodology



Online sessions               : 16 Hours

Assignments                    : 4 Hours

  • The entire programe is deivided into 5 sessions
  • Sessions are staggered over weeks.
    • Session 1 and Session 2 : 3 hours each on 07thand 08th Dec
    • Session 3 and Session 4 : 3 hours each on 14thand 15th Dec
    • Session 5 : 4 Hours on 16thDec
  • Quiz question sets in every session to ensure participants have understood the topics.
  • Assignments after every session to ensure participants not only learn the theory , examples, case studies during training but also become competent to practice by themselves.
  • 1st set of assignments between 08th - 14th Dec 2021
  • 2nd set of assignments between 15th - 16th Dec 2021
  • Answer sheets to be submitted 2 days before the next session.
  • Faculty will check, correct and reply with results.
  • Faculty will also share the correct answers, right practice of the assignments in the beginning of 3rd, 4th and 5th session
  • Final test to be conducted after 16th Dec 2021
  • Soft copies of Training Material and Case studies will be given after the training.
  • Certification issued after completion of assignments and final test

The program is designed to ensure participants can effectively learn along with their regular  work in the industry.

Fee Per Participant (Per Login)



Rs. 20000/-
+18% GST

IMTMA Members/ Micro Companies/ Individuals/ Educational Institutions / Students/ IMTMA Non Members/ Others

USD 800/-
 

Overseas Participants

Group Concession : 10% for 3 to 5 and 15% for 6 and more delegates being nominated from the same company



Participant Profile

Engineers and Executives,Junior to Senior level Managers, HODs from all functions - Production, Planning, Quality, Maintenance, Industrial engineering, Supply Chain, Operational Excellence, Design.

Faculties from academic institutes.

 


Faculty

This Program will be conducted by Mr Subrata Mitra Majumdar.

Subrata Mitra Majumdar, is a Management and Operational Excellence Consultant and a faculty of IMTMA. He is a Mechanical Engineer from Bengal Engineering College, Shibpur”, Calcutta in 1986, Six sigma Master Black Belt, Lean Black Belt, TQM trained in Japan.

He has about 33 years of regional and global experience in multiple executive roles in Business management, Profit & Loss Management, Strategy, Operations, Quality ,Safety and Environment Management, Supply Chain , New Product Development, Enterprise Operating system deployment, Operational and  Business Excellence.

He has worked with both Indian and MNCs like Anand Automotive, ABB, Saint Gobain, TATA Autocomp,     Kennametal and YG1. Some of the key positions held in my career are Quality, EHS and WCM head in Saint Gobain-Grindwell Norton Abrasives, Corporate Quality and Operational Excellence head in TATA Autocomp, Asia Pacific Operational Excellence head in Kennametal, Group Vice President Operations in Birla Precision, Global Mfg Improvement head & Managing Director in YG Cutting Tools India Operations.

Conducted training in India and outside – China,Singapore, Thailand, Malaysia, Japan, Korea, Taiwan, Australia, Israel, Germany. Trained more than 5000 people so far in last 25 years and implemented TQM, Lean Manufacturing,Six Sigma, TPM, Operational Excellenceat about 40 plants,12 countries in Asia.

Led, coached, mentored more than 2000 improvement projects that have generated financial benefits ( Top and Bottom line ) of more than 40 Million USD.

 


For More Details Contact

Santosh Singh

Programme Coordinator

Mobile :   9021442692
Email :    santosh@imtma.in

REGISTRATION : Prior registration with an online advance payment is must. Number of participants is limited and will be accepted on ‘First Come First Serve’ basis. A Certificate of participation will be issued to participants.

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