Lean Management meets Lean Engineering

Four workshops presented in the context of the Lean Management System


Take part in four Lean Industry Workshops and learn how your learning and experiences in the workshops tie into a Lean Management System. This event is a collaboration between the Lean Institute Africa and Nelson Mandela Metropolitan University.

The first event ran in May 2017 and was a great success. If you are interested in attending similar future events, please register your interest here.

LMMLE participants May 2017

Participants in the NMMU SWEAT laboratory production line simulator learning how to improve the work as part of the LMMLE programme in 2017.

More information about the workshops:

Lean as a Management System

Lean Management has come a long way from its roots in the Toyota Production System. The key principles haven’t changed, but how to effectively implement Lean Management has evolved. This presentation will outline the journey that organisations need to travel to transform to a mature Lean Management System. It will enable participants to understand the techniques they will learn about in the following workshops in the context of their organisation’s Lean journey.

Workshop 1: Lean Learning Factory Experience

The Lean Learning Factory Experience is a series of exercises conducted on an assembly line. The exercises allow participants to become part of the Gemba and experience real problem-solving teamwork. Lean management is centred around engaging all members of the organisation in continuous improvement efforts in an environment that is conducive to mutual respect. Key to this type of management is an ability to empathise with team members who operate daily at the Gemba and to understand the conditions under which they work. The Lean Learning Factory Experience is aimed at achieving this goal and will assist any Lean manager, supervisor or coach to refine their Lean teaching style and format.

Workshop 2: Value Stream Mapping (VSM)

Value Stream Mapping is an important Lean technique for exposing waste and re-configuring processes to operate more efficiently. This workshop introduces VSM and is designed to assist the participants to develop a value stream map of an assembly operation – creating a map of the current state. Tips and guidelines will be provided for drawing and analysing a current state map that reflects the reality of an operation. Participants will gain an understanding of how VSM facilitates lean thinking and in so doing, provides a framework for the application of all the tools associated with Lean.

Workshop 3: Overall Equipment Effectiveness (OEE)

OEE provides a simple means of measuring process improvement by combining three measurements that have traditionally been viewed as separate indicators of performance. A single measure that combines availability, performance and quality allows Lean practitioners to more easily monitor the success of process improvement efforts. In addition, the operators that are involved in these processes become aware of key factors that influence their continuous improvement actions – thereby allowing them to develop instinctive lean thinking patterns. The workshop covers the background to OEE, how it is typically calculated and provides valuable insight into factors that contribute to its success as a lean technique. Participants will be actively engaged in OEE calculations, data collection methods and design of typical OEE interfaces.

Workshop 4: Lean Computer Simulation

Most Lean practitioners understand the benefits of improved flow and waste elimination in their operations as these are two of the central ideas or goals of Lean Management. Achieving flow and eliminating waste are often linked to improved process layout and co-ordination. Lean Computer Simulation is a technique that has until recently been the domain of engineers with specialised training in developing simulation models that answer the more complex “what-if” questions. With the advent of more user-friendly simulation packages that allow the Lean practitioner to build visual models that can accurately predict flow and waste in sequential processes, this technique can now be deployed far more readily. Participants will be exposed to this type of simulation and will actively build a typical simulation model. A link between Lean thinking in the form of experimentation will follow to demonstrate the ability of current simulation software and the ease with which it can assist in the prediction of outcomes.

Meet the presenters:

Anton GrütterDr Anton Grütter is a Director of the Lean Institute Africa, a Lean Executive Coach and a member of the Management team. He has helped organisations to implement and institutionalise operational performance improvement programmes in industry, commerce and the public sector justice and healthcare systems for many years. He has taught operations management at South African universities since 1993. Recently he has taught at the Graduate School of Business at the University of Cape Town and as a visiting professor on the MBA programme at Shanghai University. His PhD research was on the effective implementation of shop-floor improvement teams, his textbook “Introduction to Operations Management” was published by Heinemann in 2010 and he continues to present at many international conferences.

Karl van der Merwe Dr Karl van der Merwe – Senior Lecturer, Department of Industrial Engineering, NMMU 

Karl is a senior lecturer in the department of Industrial Engineering at the Nelson Mandela Metropolitan University in Port Elizabeth. He has a keen interest in the Lean Philosophy and has undertaken a number of research and consulting projects in partnership with industrial organisations. Prior to joining academia he worked in the automotive industry and was involved in numerous improvement and capital equipment acquisition projects. To date he has written two books on Value Stream Mapping and Project Management and is currently busy with a third on Lean Operations.

Robert Oosthuizen- Simulation Consultant, Simulation Engineering Technologies

Robert is an Industrial Engineer at Simulation Engineering Technologies, the largest simulation consulting firm in South Africa.  He has a keen interest in process optimisation using simulation modelling.  He has been a part of numerous simulation optimisation studies in the mining, manufacturing, logistics and maritime industry.  Robert is also a simulation training instructor and has provided simulation training to staff of some of the largest companies in South Africa.

Erik Hagedorn-Hansen – Managing Director, Hansens Engineering and Haldan Consulting

Erik is the Managing Director of Hansens Engineering and Haldan Consulting.  Erik holds a degree in Mechanical Engineering from the University of Cape Town and an MBA from the University of the Witwatersrand. He was appointed managing director of Hansens Engineering, a family automotive component business, in 2002. He has a passion for Lean Manufacturing, especially with regard to using IT to facilitate Lean systems. Erik’s desire to share his knowledge and experience in guiding other companies along the road to lean and best business practice has led to the establishment of his management consultancy, Haldan Consulting.

Jaco Snyders – Lecturer, Department of Industrial Engineering, NMMU

Jaco is a lecturer in the department of Industrial Engineering at the Nelson Mandela Metropolitan University in Port Elizabeth. Prior to joining academia he worked in the automotive industry and was involved in numerous improvement and lean implementation projects. He manages the Centre for Business Engineering at NMMU and is currently involved in lean research.


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