Design Production Systems by applying Lean Tools

Theme: Design Production systems by applying Lean Tools


You will understand the Principles and practise of Lean that created a set of standardized work tools that systematically work towards increasing value for customers & improving profits for an organisation.


Key take-aways

  • Understanding the principle that created the application called Lean Production
  • How lean tools need to be put into practise within a production system
  • Inconsistencies within the practise of lean in organisations
  • How the interplay of Muri, Mura and Muda impacts organisation performance


About the Program

Lean has been around for nearly 30 years as we know it now, but examples of improved organisation  financial performance due to practising lean are not as easily seen. Probably because the use of loosely synchronised lean tools do not yield expected results.

This program is about building the core guiding principles of what a production operation should aim to achieve. Then every hurdle experienced is solved and converted into a standardised work or tool to be used to maintain the system .

We will start from the science behind Lean and delve into why the tools were created and how to adopt them for a type of operation. This will lead us to start with tools that will yield the best bottom line results and what needs to be done to maintain the improvement. While making sure that improvements actually show up in the measurements that we are using to keep a check on our performance.

Lean is a systems approach and hence the focus is on optimising the system out put and not on local efficiency. We will begin will tools for Muri & Mura and then mention the tools for Muda.

Most of daily management is about Muda wastes . So how does one quantify these wastes and what does value stream management show do .

In the program we will focus on understanding the cycle from order to delivery and what tools should be used to make sure the manufacturing is reducing cost.

A supplier will need to make use of different tools than an assembler and this program is about setting up an lean operation by selecting and practising tools that will help standardise the work and allow for low cost execution.

Purpose : To introduce the basic assumption on which lean was developed and the guiding the principles that drive lean . The tools that were developed to be applied to achieve the basic aim of lean. One should be able to constantly be driven in the direction of the improvement and capable enough to select the lean tool to apply for better organisation performance.

  1. Aim and Development of lean
  2. What is improvement according to lean ?
  3. Why is continual improvement very important for lean ?
  4. Understanding Muri , Mura and Muda.
  5. Tools of Muda , Muri & Mura ( Like 5S, Heijunka, Takt time, SMED, Jidoka Etc)
  6. Value Stream Mapping and managing
  7. Types of MUDA and how do we manage them
  8. How Lean tools allow for low cost operations
  9. Bringing the practise of lean into management culture
  10. Kaikaku or Kakushin – Quantum Improvements
  11. Lean Supply Chain- Supply chain Tiering and Distribution Control
  12. Industry 4.0: Using digital to improve lean operations.

Concepts and total picture of all the elements of Lean ; 6 Hours

SPOC :    Ashish Gupta ( 9999750904

 faculty  : 

Shishir Bharadwaj

About : An Avant Garde Consultant who guides manufacturing companies to develop their own capabilities for developing application and tools with the current resources which can put them on the process of ongoing improvement. Identifying strategic pathways for companies to grow without ever feeling that their process and management approach has outlived their aspirations
He focuses on effective system selection, design and implementation. His thinking and system design are deeply rooted in Theory of Constraints.

Worked in discrete manufacturing industries for 27 years and teaches that a systems approach to operations management is the only panacea for a quantum jump in productivity that the industry seeks

He is the trainer of Master Trainers for the ZED Maturity Assessment Model of QCI and the creator of Manufacturing Competitiveness e-Learning course on the Swayyam portal. .  

  • Industry Focus (Large & MSME)
    • Auto component & sub assemblies
    • Furniture Manufacturing
    • Electronic Components
    • Steel Industry
  • Area of key expertise as consultant:
    • Demand Driven Operating Model
    • Developing Operations Strategy for bottom-line improvement
    • Production scheduling & Operations Management(India Partner - )
    • ERP – implementation & Selection 

  • Area as a Trainer
    • Created the Manufacturing Competitiveness Course for eQuest (QCI)
    • Trainer of the Master Trainers for ZED Maturity Assessment Model
    • Introduction to Theory of Constraints
    • Demand Driven MRP and Demand Driven Operating Model 

  • Recent assignments
    • Improved throughput of tyre production line while reducing in process inventory, which impacted customer end stocks and higher output from the current process.
    • To improve the rate of making profit for a Rs. 100cr film Capacitor Company that has grown at 23% annually for the last 10 years. Aim to make bottom line equal to today’s top line in 5 years.
    • Improving supply chain performance , from production to retail, of a Rs 300cr  Branded furniture making company by implementing better planning and execution techniques. Aim is to increase availability by reducing inventory.
    • Planning and execution capability improvement, for a Suzuki Supplier, by Finite Capacity planning and developing new measurements that increase synchronising of departments for better due date delivery and profit.
    • Planning and optimizing  system  for a large  seamless steel tube manufacture
    • Designing and developing production scheduling system for a leading casting manufacturer
    • Enterprise wide dispersed inventory management and finite scheduling system for a AC capacitor manufacturer 

  • Consulting Resource
    • Electronics Component  Manufacturers Association of India (ELCINA)
    • Learn Committee Member of Quality Council of India
    • Lead Evaluator and Reviewer of Management Courses for eQuest 

  • Relevant  working experience:
    • 2002 – Till date                 Operations Management- improving performance of production systems
    • 1998 – Till date                 Finite Capacity Scheduling & ERP  systems
    • 1996 – 1997                      Marketing Area Manager for Eicher- Mitsubishi Trucks
    • 1993 – 1996                      Product Development- Designed & Development of Heavy        

                                                Vehicle suspension system at Eicher Mitsubishi Trucks


  • Relevant educational  achievements:
    •  Business Administration – Cardiff Business School, Cardiff, U.K
    • B.E Mechanical Engineering- Manipal Institute of Technology, Karnataka, India
    • Higher Secondary – Mayo College Ajmer, Rajasthan , India