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Lean manufacturing

Lean manufacturing is introduced as a systematic manufacturing philosophy—originally pioneered as the Toyota Production System (TPS)—aimed at delivering extraordinary results through ordinary resources by building extraordinary processes. It focuses on optimizing manufacturing systems to be low on resources and high on deliveries through the identification and systematic elimination of wastes (muda) and losses. While initially born in the highly automated automotive sector, the document details its application and adaptation to labor-intensive industries like apparel manufacturing across pre-production planning, production, quality assurance, continuous improvement, technology, space, and human resource management.

4 hr

Created by Dr. YASSER MEKKY

EN/AR [Auto]

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# Content
1 • Introduction to Lean
2 • The Seven Types of Waste & Big Losses
3 • Lean Approach to Processes & Production:
4 • Lean Approach to Quality Assurance:
5 • Lean Approach to Resources:
6 • Role of Leadership and HR in Change Management:
7 • Implementation Challenges
# Outcomes
• Substantial reduction or elimination of waste (muda), excess inventory, Work in Progress (WIP), and lead times.
• Major improvements in product quality, achieving "Right First Time" (RFT) execution, and lowering reworks and rejection rates.
• Increased operational productivity, higher Overall Equipment Effectiveness (OEE), floor space savings, and overall cost reduction.
• Enhanced employee morale, motivation, team spirit, and participation through structured problem-solving and leadership development.
# Participants
1
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Designed for manufacturing professionals, top management, middle management, industrial engineering (IE) teams, quality assurance personnel, human resources agents, and operational leaders involved in production management and business process re-engineering.