This course focuses helps
manufacturing lead personnel, supervisors,
managers, manufacturing engineers, QA personnel, and schedulers develop their
leadership and supervisory skills. The course addresses the unique
challenges inherent to a manufacturing organization. The Manufacturing
Leadership program is intense, it is
based on real-world manufacturing management experience, and it is focused on
a comprehensive and intensive 3-day training program that presents the
essential elements of an effective and proactive manufacturing management
system, with a special focus on developing strong first-level
manufacturing management teams.
Topics include lead person, supervisor, and
executive manager roles in the manufacturing environment, and how these key
influence quality, cost, and delivery performance.
This is a practical
course taught from the perspective of an experienced manufacturing
manager, with a special emphasis on real-world solutions, the “nuts and
bolts” of manufacturing leadership, and delivering conforming products on
schedule. The course develops
and presents a results-oriented roadmap for implementing an effective
manufacturing management syst
will learn how to:
Develop an effective leadership development system.
Objectively identify manufacturing improvement
Work together to improve your manufacturing team.
Identify and address the causes of delinquent schedule
Historical manufacturing perspectives.
Manufacturing enterprises. Organizational
Leadership traits and styles. Characteristics
of a good leader. Situational
leadership. Supervision versus
versus organizational position.
3: Theories of Motivation.
personality styles. Maslow’s
hierarchy of needs. The
power/achievement/affiliation motivation model.
Identifying individual motivational factors.
Motivators and demotivators. Group
4: First-Level Supervision.
responsibilities and authority. Supervisor
responsibilities and authority. Maintaining
the supervisor/subordinate relationship.
Selecting leads and supervisors.
Coaching leads and supervisors.
Role of the lead and supervisor in shaping the culture.
5: Building a Manufacturing
development. Elements of a
successful team. Building trust. Cross
6: Work Assignment.
production control challenge. Planning,
scheduling, and priorities. Matching
individuals to work requirements. Basic
MRP/ERP operating systems. MRP/ERP
dispatch lists and transactions. Lead
and supervisor work assignment responsibilities.
Session 7: Manufacturing Standards.
standards. Standards accuracy
issues. Standards updating .
Making standards effective. Communicating
standards. Lead and supervisor
standards responsibility. Group
Measuring and Improving Productivity.
Utilization definition. Productivity
and utilization challenges. Identifying
productivity and utilization detractors.
Delay ratio analysis. Efficiency
evaluation. Recognizing and
rewarding superior productivity. Lead
and supervisor productivity responsibility.
9: Assessing Capacity and
and load definition. Using
standards for load determination. Comparing
capacity versus load. Theory
of constraints. Identifying
and resolving production bottlenecks.
Lead and supervisor capacity and load assessment responsibility.
Improvement opportunities. Group
assignment and authority. Overtime
budgets and budget monitoring. Assessing
overtime effectiveness. Lead
and supervisor overtime responsibilities.
Session 11: Quality. Quality definition.
Quality responsibility. Prevention
versus detection. The
inspection function. Lead and
supervisor quality responsibilities. Quality
measurement and reporting.
12: Problem Solving.
problems. The 4-step problem
solving process. Identifying
all potential causes. Converging
on most-likely causes. Corrective
action identification and implementation.
Lead and supervisor problem solving responsibilities.
Knowing when to call for help.
13: Conflict Management.
nature of conflict. Identifying
and understanding conflict. Positive
and negative aspects of competition. Resolving
conflict. Lead and supervisor
conflict resolution responsibilities.
Session 14: Training. Job-specific success factors.
Recognizing training needs. Training
newly-assigned personnel. Refresher
Lead and supervisor training responsibilities.
Session 15: Work
Center Organization. Work center definition.
Work flow. Lean
manufacturing concepts. Cellular
manufacturing. Work center
cleanliness. 5S and Mr. Clean
programs. Lead and supervisor
16: Visual Manufacturing and
metrics. On-time delivery
metrics. Overtime metrics.
Utilization metrics. Schedule/MRP
compliance metrics. Metrics
posting. Lead and supervisor
purposes. Interview questions.
Interview preparation. Overcoming
interviewee reluctance. Selling
the organization. Group
18: Time Management.
time management. Lead,
supervisor, and manager time management considerations.
Keeping a personal schedule. Prioritizing.
purposes. Meeting logistics.
Minimizing meetings. Agendas.
Meeting follow-up. Supervisor
work from quality and productivity perspectives.
Providing feedback. Eliminating
blame, fear, and intimidation. Recognizing
and rewarding superior performance. Knowing
when to ask for help. Lead and
supervisor responsibilities. Improvement
Session 21: Staying
on Schedule. Delinquent delivery root causes. Process yield.
Productivity. Supplier performance. Purchasing. Planning.
Organization. A delivery performance improvement roadmap.
Course Wrap-Up. Course review. Developing
a follow-on action plan. Course evaluation.