Not every production line needs to be extensively modified to your specific requirements after delivery. Subsequent multi-costs in the order of tens of percent of the original price of the technology for optimizations, process rebalancing, SW programming, ergonomics, etc. can be significantly avoided by properly designing the technology concept and creating a concrete specification for the supplier. This training will teach you how to prepare optimal production line concepts, detailed specifications for technology suppliers and avoid problems while they are still on paper and cost you almost nothing to solve.

Every manufacturing facility needs new production technology from time to time, whether it’s just a single-purpose production equipment or a fully automated production line that produces, controls and fill final products into customer packagings without human touch. To significantly increase the chances of fully meeting customer requirements without significant additional overhead and at the same time integrating the new technology into your internal systems, it is advisable that the line be designed by the people who will be responsible for and work on the line in the future. Only by adopting this approach you can prevent the errors and deficiencies that previously caused challenges with older generations of production technology. In doing so, you can effectively apply your expertise and best practices to the new technology.

Lean Line Design is a collaborative methodology that empowers local teams to shape their own manufacturing facilities while learning from past mistakes. This straightforward, 15-step program guides you through everything – from initial “Takt-Time” calculations and operation balancing to layout and material flow design, culminating in a final simulation of the solution using “Cardboard.”

Through this workshop, you’ll not only crystallize your vision but also provide a clear blueprint for the technology manufacturer tasked with bringing your ideas to life. As a result, your team will eagerly anticipate seeing their proposal come to fruition and will push for the swift integration of the new technology.

A key advantage of this approach is its ability to minimize resistance to change, which typically arises when technology is introduced without input from those who will use it, ultimately leading to smoother transitions and more successful implementations.

The course concludes with a brief assessment, and upon successfully carrying out the hands-on tasks outlined in the assignment after completing the course, you can earn the prestigious “Lean Line Designer” certificate. We’re here to support you throughout the practical phase with online guidance sessions conducted by our tutor. The cost of the course covers both the certification process and this extra personalized coaching.

You will learn to

  • Perform foundational calculations such as Takt Time (TT) and Cycle Time (CT).
  • Generate an overview of part assemblability and identify value-added steps.
  • Select suitable assembly methods for each step of the assembly process.
  • Analyze the practical CT against machine capacity limitations.
  • Construct an effective material flow plan.
  • Measure time taken for production steps to enable basic balancing.
  • Determine the optimal number of operators needed.Document issues encountered in other lines, as well as gather successful practices.
  • Sketch a clear block diagram of your process flow.
  • Devise control steps necessary for your proposed process.
  • Establish packaging guidelines and material flow strategy.
  • Create a true-to-scale layout design.
  • Balance and optimize your process flow.
  • Refine your process through “Cardboard” simulations for debugging.
  • Develop a comprehensive implementation plan.

The training is intended for:

  • Technologists
  • Project managers
  • Specialists from the AM department
  • Corporate manufacturing specialists
  • Managers in manufacturing
  • Lean / CI managers

Available Terms