IND 251 - Maintenance Principles

1. Define key Lean Manufacturing terms and principles
   1. Define common Lean terms such as waste, value, takt time, kaizen, and flow
   2. Identify the Eight Wastes
   3. Define the goals and origins of Lean Manufacturing
2. Describe the benefits of Lean practices in a manufacturing environment
   1. Describe how Lean improves quality, cost, delivery, safety, and morale
   2. Explain the difference between value-added and non-value-added activities
   3. Describe the impact of Lean on productivity
3. Identify Lean tools and their applications
   1. Identify tools such as 5S, Value Stream Mapping, Kanban, mistake proofing, and visual management
   2. Identify the role of standard operating procedures in Lean systems
   3. Identify the appropriate Lean tool for a given situation
4. Explain 5S in the workplace
   1. Explain each of the 5S steps: Sort, Set in Order, Shine, Standardize, Sustain
   2. Describe how 5S contributes to workplace efficiency and safety.
   3. Explain how 5S is used for continuous improvement
5. Create a basic value stream map for a manufacturing process
   1. Identify value-added and non-value-added activities
   2. Break down a production process into discrete steps
   3. Analyze sources of waste or inefficiency in the process
   4. Indicate inventory levels, process times, and information flow
   5. Develop a future state map with suggested Lean improvements
6. Apply root cause analysis tools, including the Whys and Failure Modes and Effects Analysis (FMEA)
   1. Apply the 5 Whys technique to trace the root cause of a manufacturing proble
   2. Use FMEA to identify potential failure modes in a process or product
   3. Document the severity, occurrence, and detection ratings in an FMEA worksheet
   4. Recommend corrective actions based on root cause findings to prevent recurrence