Lean in the Chemical Industries

Applying Lean in the Process Industries

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Course Outline

• What is Lean – its origins, aims and successes
• Why would you want to apply Lean?

• The 5 Lean Principles - an Overview of a Lean organisation

• Lean Concepts
• Work and 7 Wastes, Overburden & Unevenness - how to spot opportunities to remove cost an increase throughput
• The Kaizen Flag - the correct order to approach improvements
• Standard Work - Reducing variation, improving control, making problems obvious

• Common Lean Tools - An Introduction
• Workplace Organisation (5S) - It is so much more than housekeeping
• Visual Management – Communicating with and enabling the team
• Measurement – How to measure performance (including batch chemicals)
• Process Mapping – an introduction to finding more opportunities to improve
• SMED for Chemicals – we don’t make cars, so what use is it?
• Practical Problem Solving - Structured approach to tackling problems

• Lean Management Systems

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Training Notes –

A full hardcopy set of the slides and handouts will be given to all delegates attending the course

What is Lean?

Lean involves never ending efforts to eliminate or reduce waste – so you end up doing more with less. Adopting Lean techniques helps companies become more competitive and efficient with time and resources, giving bottom line benefits.

Lean has been evolved and honed over decades of application in many companies, most notably in Toyota (as the Toyota Production System, or TPS).

As an approach, Lean is proven to be successful at creating high levels of operational excellence in organisations. Any organisation wishing to be competitive and successful in its market and to remain so will have to implement some form of operational excellence and ongoing continuous improvement.

This course shows you the best approach available - Lean.

The common Lean tools and techniques will be introduced, and each placed in the context of the process industries. Some of the pitfalls of applying Lean in a chemical environment are highlighted, as well as work arounds and solutions.

Case studies and examples from the process industries are used throughout the course, with time given to explore how the tools and techniques covered may have to be adapted to each delegate’s environment.

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Who Should Attend?

An introduction to Lean by an experienced process industries Lean practitioner to give a non-automotive view of Lean. This course is suitable to those interested in or charged with implementing Lean techniques within their organisations, such as:

• production front line supervisors,
• managers,
• engineers, and
• those with an interest in continuous improvement.

For those sites already started on their Lean journey, this course will be valuable for new staff and those about to become involved in improvement teams to introduce them to Lean concepts, tools and terminology.

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Further courses are available that look at specific tools and techniques of Lean in more detail, including:

• Changeover Reduction (also known as SMED)
• Running Kaizen Events
• Standard Operating Procedures/ Standard Work
• Lean Supply Chains
• Value Stream Mapping
• Visual Factories

This is not an exhaustive list of Lean tools and techniques. If there are other topics you are interested in please ask.