Course Syllabus

Creating Mixed Value Streams (Module A):

1. Introduction
   1. Course structure
   2. Determining your value stream type
   3. Our case study, EMC Stamping
   4. Mixed Model Value Stream challenge
2. Determining product families:
   1. The Product Family Matrix
   2. Differentiating processes for the Product Family Matrix
   3. Selecting families with shared vs. dedicated equipment
   4. Alternate processing
   5. Work content considerations
   6. Refining product family groupings using mixed model guidelines
   7. Practical exercise
3. Takt Time at the pacemaker:
   1. Takt time definition
   2. Takt capability
   3. Individual vs. family demand
   4. Mixed model takt time calculation
   5. Practical exercise

Creating Mixed Value Streams (Module B):

1. Calculating equipment needs:
   1. Machine vs. manual processing
   2. Equipment cost considerations
   3. Calculating machines required
   4. Machine loading charts
   5. Impact of waste on machine loading
   6. Practical exercise
2. Determining the interval:
   1. EPEI definition
   2. Inventory and lead-time implications
   3. The Chaos Curve
   4. Determining for changeover time needed to support intervals
   5. Practical exercise
3. Developing product balance charts:
   1. Operator work balancing
   2. Planned cycle time
   3. Options when work cannot be balanced
   4. Separating operator from machine
   5. Average weighted cycle time
   6. Practical exercise
4. Balancing flow for the mix:
   1. Balancing for flow by sequencing
   2. Balancing for flow by varying labor
   3. Worker flexibility in cell design
   4. Determining value stream type
   5. Balance chart refinements
5. Creating standard work for the mix:
   1. Definition of standard work
   2. Standards within skill levels
   3. Determining “best” methods
   4. Cross-functional determination of standards
   5. The scientific method
   6. Visual method sheets

Creating Mixed Value Streams (Module C):

1. Creating pitch at the pacemaker:
   1. Pitch definition
   2. Management timeframe
   3. Five pitch considerations
   4. Train-route pitch example
   5. Calculating and establishing pitch
   6. Creating the schedule (or heijunka) box
   7. Floating and inverse pitch
2. Scheduling the mix:
   1. Mix analysis
   2. Developing and using mix logic charts
   3. Loading the schedule box
   4. Flexible labor implications
   5. Practical exercise
3. Dealing with changes in customer demand:
   1. Designing flexible supermarkets
   2. Operating flexible supermarkets
   3. Seasonality in demand
   4. Developing multiple future-state modes
4. Summary
   1. Review of course concepts
   2. Checking our work against EMC Stamping’s business objectives