This workshop centers on developing the skills and tools needed to perfect factory operations and link the success of DFT within the factory walls to enterprise order-to-cash fulfillment across the value chain.
Participants in this 4-day workshop walk away with the following skills, knowledge and understanding:
- Gain a solid understanding and working knowledge of how the DFT Business Strategy can benefit your organization.
- Learn to power operational efficiency, drive on-time delivery leadership and supplier consistency.
- Avoid the “Random Acts of Lean” trap with a consistent & sustainable system.
This first workshop in the Demand Flow series of training focuses on learning the mechanics and principles involved in creating an agile factory. Speed and response are two of the most important factors in driving to demand. Demand Flow Technology (DFT) paves the way to harness the power of driving to demand with what media industry analysts have coined “the science behind pull and flow”. This workshop centers on developing the skills and tools needed to perfect factory four-wall operations and pave the way towards success in the larger picture of the enterprise by linking the success of DFT to enterprise order-to-cash fulfillment across the entire value chain of the business.
The workshop starts from a cash perspective, from cycle time to working capital to cash conversion. Students learn about customer demand and its relevance in creating a solid foundation of production flow while also working with process variation across flow with optimization and flexibility. DFT uniquely integrates process and supply chain design with pull replenishment and flexible employee strategies. Pull system design and Kanban sizing calculations are best practiced in the hands-on truck and trailer demonstration factory. This opens up a bigger conversation about managing change, integrating people in the process and measuring performance, followed by understanding how to leverage the knowledge and using that to create sustainable performance with effective planning and supplier integration. An operational excellence program framework enables the extension of DFT across the entire organization to sister divisions and other facilities as well as create capable suppliers.
TOPICS COVERED
- Introduction
- Demand Flow Technology
- Our Process of Learning
- Demand Driven Value Chain
- The Perfect Order
- Product Cost & Labor
- DFT Tools
- Product Synchronization
- Sequence of Events
- Demand at Capacity
- TAKT / Operational Cycle Time
- Process Map
- Resource Calculation
- Line Balancing
- Speed and Flexibility
- TPCT
- Employee Flexing
- Method Sheets
- Operational Definition
- Pull Design
- Material Kanban
- Replenishment Execution
- Engineering Documentation and Control
- Bill of Materials
- Field Replaceable Units (Spares)
- Engineering Change (ECO)
- Managing Flexible Employees
- Certification and Training
- Job Skill Assessment
- Compensation and Incentive
- Planning and Daily Execution
- Demand Driven Flexibility
- Daily Resource Planning
- DFT Sequencing
- Lean Scheduling Practices
- Prioritization
- Linearity
- Operational Excellence and Lean Tools
- Operational Excellence
- Lean Concepts (Elimination of 7 types of waste)
- Random Acts of Lean
- Implementation Planning
- 5S: an Overview
- Visual Factory
- Setup Reduction
- Total Predictive Maintenance
- Six Sigma
- DFT & DMAIC Overlay
- DFT Execution in Machine Cells
- Recovery of Setup
- Machine Cells
- Dual Card Kanban
- Utilization
- Financials and Other Metrics
- Traditional vs Flow Based Costing
- Working Capital
- Value Chain Expense
- Inventory Turns
- Cash Conversion
- Free Cash Flow
- Building the DFT Factory: Practical Implementation Workshops
- Sequence of Events
- Operational Definition
- Material Kanban
- Engineering / Bill of Materials
- Employee Certification: Building in a DFT Environment
- Planning and Resource Calculations
- Line Live
Each of these areas is broken down and reinforced with "real-world application" exercises and live hands-on learning labs and simulations.
Who should attend?
Participants in this workshop include:
- Discovery Teams
- Executives
- Implementation Leaders
- Plant Managers
- Human Resources
- Manufacturing Engineers
- Union Representatives
- Production Supervisors
- Production Planners
- Material Handling Managers
- Facilities & Maintenance
- Buyers
- Design Engineers
- Implementation Team
- Black Belts
- Suppliers
- Customers
ENROLLMENT FEE
The enrollment fee for this workshop is $2,185 per person.