Brochure - Lean the Process Flow Profile

Lean the Process Flow

“For companies that want to produce more, in less
time, and at a higher quality than ever before”

In a Nutshell:

Lean the Process Flow is an advanced, enterprise-level lean course that
provides a structured approach to the definition, analysis and improvement
of processes. This course offers the “meat and potatoes” techniques--
including process flow mapping, bill-of-activity structures, lean
production cell design, standard workflow, and workstation design--for
designing processes without waste. Companies that apply the concepts in
this course will:

• Master a step-by-step approach to lean process design in both
manufacturing and service processes,
• Optimize flow of work,
• Reduce expensive inventory levels,
• Eliminate non-value-added steps in the production process,
• Avoid overstaffing and overproduction,
• Shorten lead times and reduce customer wait time,
• Create a clean, safe “showplace” of a work environment,
• Build a strong foundation for continuous improvement,
• Reduce costs associated with rework, scrap, and equipment
downtime,
• Develop standardized, best-method training guides for new
employees, and
• Provide consistent quality.

Specifically, participants who successfully complete the course will know
how to:
• Create current and future process flow maps
• Baseline the process
• Identify and evaluate the aspects of lean process design
• Learn to manage the deployment of the 5 Star Lean Toolsets (Teamwork, Flow,
Pull, Quality and Equipment)


Duration: Five days

Dates: April 25 - 29, 2005 Register today—Class size is limited!

Location: Knoxville, Tennessee

Tuition: $3,950 per person (includes meals and lodging)


Who Should Attend:

If you would like to help your company produce more product, in less
time, and at higher quality than ever before, YOU should attend this
course--or make sure the appropriate operations personnel register
immediately!

Lean the Process Flow is designed for operations personnel, including
plant managers, production managers, department managers, and section
chiefs in administrative and manufacturing processes. The course also is
ideally suited for manufacturing engineers and persons involved in
technical process support disciplines. Moreover, within service industries,
anyone who deals with processes—e.g., a bank manager or and insurance
sales manager—will find the course extremely beneficial.

Large companies who are implementing lean throughout the entire
enterprise should train numerous operational personnel in Lean the
Process Flow. Graduates of the Lean the Process Flow advanced course
serve as Champions of deployment at their specific work sites. Champions
advance the dissemination of the lean culture by managing the work of a
number of Skill Coaches who execute various toolsets throughout the
system. In other words, Champions are the architects of lean
transformation: they understand lean process design and deployment, and
they utilize Skill Coaches to implement their designs.

Moreover, Lean the Process Flow is part of the training material designed
for those who wish to earn an Enterprise Black Belt. The Enterprise Black
Belt Certification is designed for people who have functional roles at the
site, business unit, or corporate level and wish to assist a business unit as it
goes through a Lean Enterprise transformation. The Enterprise Black Belt
is the logical “next step” for lean or six sigma Black Belts. For more
information about the requirements for Enterprise Black Belt Certification,
please contact the Greenwood Lean Enterprise Center.





Course Outline:

I. Baseline Analysis: Learn how to conduct a baseline analysis of the
current process in preparation for creating the lean process design.
The baseline includes:
A. Product Anatomy
B. Process Structure
C. Process Flow Mapping
D. Process Analysis
E. Process Cost Analysis

II. Lean Process Design: Learn how to design lean processes that can
provide a wide variety of products (goods & services) of the
highest quality, in less time and at a lower cost than anyone else
worldwide. Learn the advanced level techniquest to:

A. Establish Flow Paths (maps & designs)
B. Establish Point of Use (people, equipment, materials and
information).
C. Establish pull (in process, linked process, and materials)
D. Establish a visual factory with built in quality
E. Learn how to build to demand (rate, mix, variation, cycle, and
configuration)
F. Learn how to schedule, execute and manage lean process for
complex, mixed-model situations


Faculty:

The programs of the Greenwood Lean Enterprise Center are co-sponsored
by the University of Tennessee Center for Executive Education and Lean
Works, Inc. Faculty of the University of Tennessee and Lean Works
facilitators are experienced in implementing lean worldwide in numerous,
diverse industries such as the following:

Continuous Process Industries
• Carpet and paper mills
• Cheese processing equipment
• Rubber roofing and waterproofing products
• Rubber automotive brake seals

Manufacturing
• Heating, air conditioning, and refrigeration
• Aircraft
• Electrical power distribution equipment, controls, and electrical
components
• Lawn and garden equipment
• Automotive equipment and systems
• Transportation and construction equipment
• Injection molded plastics
• Fire safety and piping systems
• Investment castings

Remanufacturing (Repair and Overhaul)
• Aircraft engines, airframes and materials
• Compressors

Engineer to Order
• Special isolation equipment and barrier systems
• Specialized food processing equipment

Service Industries
• Hospitals
• Medical service providers
• Transportation and Distribution


Dr. Tom Greenwood currently serves as Executive in Residence with the
University of Tennessee center that bears his name in recognition of his
contributions to lean knowledge and training. Also, Dr. Greenwood is
President of Lean Works, Inc. In addition to a career as an academician at

the University of Tennessee—where he founded the Lean Enterprise
Design Institute—Dr. Greenwood has served in a variety of manufacturing
positions, including materials management, plant operations, and as the
Director of Global Manufacturing Systems for United Technologies-
Carrier Corp. where he was responsible for the implementation and
improvement of lean product delivery systems for more than sixty plants
worldwide. His workshops on lean concepts have been taught to over
10,000 managers and implemented in 28 countries. More than 150
business units from Fortune 500 companies have transformed their
businesses using Dr. Greenwood’s Lean Implementation System
methodology. Dr. Greenwood has published articles in both academic and
trade journals on implementation strategies for deploying lean production
concepts and using activity-based models to improve business processes.
He is a member of the Society of Manufacturing Engineers and the
Production and Operations Management Society and is a former Director
at Large for the Institute of Industrial Engineers. He received his Ph.D. in
industrial engineering from the University of Tennessee.

Facilities:

Classes are held in the executive classrooms at the University of
Tennessee Center for Executive Education. These facilities are designed to
promote group interaction in an environment conducive to applied
discussions, feedback and the development of relational networks that
frequently continue well beyond the on-campus experience.

Accommodations are single-occupancy rooms at the nearby Knoxville
Hilton Hotel. Transportation from the hotel to the Center and to dining is
provided.
Contact:

For more information on this or any Advanced Lean Course, please
contact:

Rhonda Barton or Judy Snow
Associate Director Program Coordinator

Center for Executive Education
College of Business Administration
The University of Tennessee
708 Stokely Management Center
Knoxville, TN 37996-0575

Phone: 865/974.5001 E-mail: [email protected]
Fax: 865/974.4989 Web: http://TheCenter.utk.edu



Other Advanced Courses Available:

The Greenwood Lean Enterprise Center offers four advanced, enterprise-level courses
designed to help organizations apply lean across the entire value chain, from supply to
the end customer. In addition to Lean the Process Flow, the Greenwood Lean Enterprise
Center also offers:

• Go Configure to Demand (applying lean to Sales, Marketing, and Design)
• Rate-Based Operations Planning (applying lean to Planning)
• Establish Pull from Customer Through Supply (applying lean to Supply Logistics)

It is strongly recommended that companies send representatives to each of these
advanced courses in order to build a fully functioning, fully trained Enterprise
Implementation Team whose expertise spans the entire product/service delivery system.