Purdue Manufacturing Extension Partnership

Lean Manufacturing

register for events Lean Manufacturing

Build a Lean Enterprise

Lean services focus on eliminating non-value-added activities from a company's processes while streamlining its value-added activities. It is a people-oriented approach that empowers a team to take action to achieve improvements. Lean tools and implementation are the best way to effectively utilize a company's most valuable resource… its people.

Indiana MEP utilizes the lean training tools developed by MEP University, thus giving our clients a lean tool kit that is nationally recognized and delivered via the MEP network of Centers throughout the United States.

Our lean services include:

  • Principles of Lean Manufacturing

    A one-day workshop with a “live” simulation that guides you through the transition from a traditional manufacturing approach to that of a lean manufacturing environment! Waste is eliminated, productivity increased, and you gain a competitive edge in the marketplace.

    Principles of Lean Manufacturing, or Lean 101 as we call it, are part of an integrated suite of Indiana MEP tools and services developed specifically for manufacturers. This course is one in a series of related lean courses that we offer. At this workshop you'll learn the principles of lean manufacturing and how to apply them. During the simulation exercises, as a member of the production team for Buzz Electronics, you'll apply lean concepts such as standardized work, visual signals, batch-size reduction, pull systems and more. Experience firsthand how lean improves quality, reduces cycle time, improves delivery performance, reduces WIP and enables Buzz to show a profit. This one-day class is the ideal beginning for your company's lean training program.

  • Value Stream Mapping (VSM)

    Learn how to create a value map of your current-state and future-state processes. This technique helps the manufacturer understand the total flow of the value stream, see the sources of waste, determine common language about the process, show links between information and processes, develop an improvement plan, and prioritize activities. Participants learn how to eliminate the waste in the system and achieve dramatic improvements to their processes.

  • 5S System - The Visual Workplace

    This program offers you an opportunity to experience first-hand how the 5S System reduces waste in the mounting plate assembly area of a simulated production facility. Participants learn the concepts of the 5S System and then apply them to transform a cluttered, disorganized production area into a clean and orderly workplace. On Day Two of 5S training, we apply 5S techniques to an area in your facility.

  • Quick Changeover/Set-Up Reduction

    Participants learn the fundamentals of set-up reduction in applying quick-change thinking to any type of setup or industry. This training focuses on attaining quick changeover through the systematic elimination of the internal components of a setup, while streamlining the final procedure. Reductions in set-up time mean you can produce in smaller lots, thereby making a greater variety of products in the same amount of time.

  • Cellular/Flow

    This hands-on course teaches how to link and balance manufacturing operations to reduce lead times, minimize work-in-progress (WIP) optimize floor space usage and improve productivity. The instructor will lead participants through a proven and reliable methodology for designing and implementing work cells. This training applies to both assembly and machine-based processes.

  • Total Productive Maintenance (TPM)

    Learn about Overall Equipment Effectiveness (OEE) and how it relates to capacity. Apply TPM principles and techniques to equipment in a hands-on simulation and experiences how applying TPM can achieve dramatic improvements in uptime and increased capacity.

  • Pull Systems/Kanban

    Learn how to control resources in a production process by replacing only what have been consumed. Introduces the principles of Pull systems/Kanban, applies them in a lifelike simulation, and demonstrates how they can be applied to a variety of manufacturing situations.

  • Lean Product Development

    This workshop presents a comprehensive set of practical, easily applied techniques for reducing the manufacturing cost of any product. Participants learn how to apply these powerful tools to real products, in real time, with high efficiency. The practical tools described in this workshop can be applied to both new Product opportunities and existing successful products, require minimal organizational change, and can yield immediate bottom-line results. The tools and methods in this course are organized into an "itinerary" that follows the timeline of a typical product development project, from the initial idea generation to product qualification and launch. Examples, exercises, and guidelines are provided for each tool to help the student decide whether that tool would be valuable in their situation.

Advanced Problem Solving One-Day Workshop

This one-day workshop provides the background and skills necessary to lead an effective, structured, team-based, analytical approach that detects potential problems and thus alleviate chronic failure problems within an organization. Learn how to apply several techniques to detect, identify, analyze and solve performance problems by understanding variation, and uncover root causes and apply the Lean Six Sigma DMAIC problem solving approach. Be exposed to several techniques that help reduce waste, eliminate organizational inefficiencies, determine weaknesses in systems and processes, and reduce human error. Topics include Brainstorming, Affinity Diagrams, Cause and Effect Diagrams, 5 Why's, 20 Questions, Run Charts, Histograms, Pareto Analysis, and Decision Tree Analysis.

Please email tapmep@purdue.edu if interested in on-site training or view our public offerings.

Also Available: Lean Overview One-Day Workshop

This one-day workshop is designed to provide Managers and Leaders with an overview of Lean Manufacturing concepts and Lean Behaviors necessary for successful change. Learn the basic foundation of Lean by addressing basic disciplines including Value Stream Mapping, Standardized Work, 5S, Error Proofing, Quick Changeover, TPM, One Piece Flow, Pulls Systems, Kanban and Visual Control. The core idea is to maximize customer value while minimizing waste. A lean organization understands customer value and focuses their key processes to continually meet those needs.

Please email tapmep@purdue.edu if interested in on-site training or view our public offerings.