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Session 1: Introduction
- Course content
- Historical manufacturing perspectives
- Manufacturing enterprises
- Organizational approaches
- Organizational cultures
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Session 2: Leadership
- Leadership
- Leadership traits and styles
- Characteristics of a good leader
- Situational leadership
- Supervision versus management
- Executive management
- Responsibilities versus organizational position
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Session 3: Theories of Motivation
- Hunsaker-Allesandra personality styles
- Maslow’s hierarchy of needs
- The power/achievement/affiliation motivation model
- Identifying individual motivational factors
- Motivators and demotivators
- Exercise
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Session 4: First-Level Supervision
- Lead 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
- Exercise
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Session 5: Building a Manufacturing Team
- Team development
- Elements of a successful team
- Building trust
- Cross training
- Competition
- Exercise
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Session 6: Work Assignment
- The nature of the production control challenge
- Planning, scheduling, and priorities
- Matching individuals to work requirements
- Basic MRP operating systems
- MRP dispatch lists and transactions
- Lead and supervisor work assignment responsibilities
- Improvement opportunities
- Exercise
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Session 7: Manufacturing Standards
- Standards definition
- Developing standards
- Standards accuracy issues
- Standards updating
- Making standards effective
- Communicating standards
- Lead and supervisor standards responsibility
- Exercise
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Session 8: Measuring and Improving Productivity
- Productivity definition
- 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
- Exercise
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Session 9: Assessing Capacity and Load
- Capacity 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
- Exercise
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Session 10: Overtime
- Overtime definition
- Overtime assignment and authority
- Overtime budgets and budget monitoring
- Assessing overtime effectiveness
- Lead and supervisor overtime responsibilities
- Exercise
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Session 11: Quality
- Quality definition
- Quality responsibility
- Prevention versus detection
- The inspection function
- Lead and supervisor quality responsibilities
- Quality measurement and reporting
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Session 12: Problem Solving
- Identifying 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
- Exercise
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Session 13: Conflict Management
- The nature of conflict
- Identifying and understanding conflict
- Positive and negative aspects of competition
- Resolving conflict
- Lead and supervisor conflict resolution responsibilities
- Exercise
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Session 14: Training
- Job-specific success factors
- Recognizing training needs
- Training newly-assigned personnel
- Refresher training
- Manufacturing instructions
- Lead and supervisor training responsibilities
- Exercise
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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 responsibilities
- Exercise
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Session 16: Visual Manufacturing and Communications
- Productivity metrics
- On-time delivery metrics
- Overtime metrics
- Utilization metrics
- Schedule/MRP compliance metrics
- Metrics posting
- Lead and supervisor responsibilities
- Exercise
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Session 17: Interviewing
- Interview purposes
- Interview questions
- Interview preparation
- Overcoming interviewee reluctance
- Selling the organization
- Exercise
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Session 18: Time Management
- Personal time management
- Lead, supervisor, and manager time management considerations
- Keeping a personal schedule
- Prioritizing
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Session 19: Meetings
- Meeting purposes
- Meeting logistics
- Minimizing meetings
- Agendas
- Meeting follow-up
- Supervisor responsibilities
- Improvement opportunities
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Session 20: Counseling
- Assessing 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 opportunities
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Session 21: Staying on Schedule
- Delinquent delivery root causes
- Process yield
- Productivity
- Supplier performance
- Purchasing
- Planning
- Organization
- A delivery performance improvement roadmap
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Session 22: Course Wrap-Up
- Course review
- Course evaluation