Mixed Model

Mixed Model Value Flow Workshop Overview

KAIZEN Institute Lean Advisors offers professional on-site training at your facility. Participants learn hands-on how to manage products in a mixed model environment.

The Mixed Model workshop is for the more advanced KAIZEN Lean Practitioner. The company will have a completed Current and Future State Enterprise Value Stream Map. It is typically introduced in the KAIZEN Lean journey as a tool to deploy when the company / student is faced with products with significantly different cycle and process times that are competing for the same resources. Often, the workshop is part of the overall KAIZEN event identified in the Implementation Plan. It teaches the student practical ways to manage the different products through the Enterprise Value Stream in order to optimize Flow and Pull, and eliminate process waste. Practical on-floor exercises help the students to practice what they are learning - as they learn.

The workshop facilitator spends a total of five days at the host company. The workshop promotes a knowledge transfer with a mixed concept presentation and practical in-class case study work, followed by actual application of concepts with a specific family of products within a defined Enterprise Value Stream. All workshops are designed for maximum interaction and participation, optimizing the learning of all participants.

Learning Objectives

• Define Mixed Model


• Identify Product Families within the defined Enterprise Value Stream


• Understanding Mixed Model applications to achieve your Future State


• Identify Shared Resources within the Enterprise Value Stream


• Understand relationships of Takt Time, Batch Size and Capacity


• Apply techniques to manage in a mixed model environment

Program Agenda

This 5 Day Mixed Model Workshop is best conducted with a core group of people over 5 consecutive working days. This provides adequate time for learning and immediate applications.

Mixed Model - Day One

• Introduction and KAIZEN Lean Review


• What is Mixed Model?


• The Key Questions in a Mixed Model environment


• Validate Future State and Implementation Plan

Mixed Model - Day Two

• Understanding Customer Demand


• Understanding the work content of each product within its family


• Determining and Understanding the Pacemaker


• Working in the Pacemaker Loop, the Leveling and Scheduling Loop, the Shared Resources Loop, and the Supplier Loop

Mixed Model - Day Three

• Determining the Takt Time, Equipment Capacity, Batch Size, and Takt Image


• what is your Interval (EPEI) for each Product Family?

Mixed Model - Day Four

• Making Value Flow


• Operator Balance Charts


• Standardized Work


• FIFO Lines


• Pull Systems

Mixed Model - Day Five

• Pitch at the Pacemaker


• Constructing a Heijiunka Box for the Pacemaker


• Sizing Your Finished Goods Supermarket

Mixed Model Summary - At the end of the workshop

• Implementation Planning for Your Mixed Model Value Stream


• Continuous Improvement


• Mixed Model Workshop conclusion

Who Should Attend?

• Value Stream Leaders


• Engineers


• Production Associates


• Kaizen Team Members

Prerequisites

• Completion of Introduction to Lean


• Valid Current and Future State Maps with Implementation Plan


• Experienced KAIZEN Lean Practitioners

Contact Information