Implementation methods of Lean Management with practical exercises in automotive factory

Abstract

Page 7 Abstract The fastest and most effective way of training employees in the method of lean production is to create your own image from the experience obtained during the training. In the current turbulent times it is not possible for a worker to participate in the implementation of lean manufacturing to obtain a perfect practical knowledge and on the other hand, only a theoretical training without practical implementation is often not effective. Therefore, a combination of theoretical knowledge of lean methods with a practical training using simulation games on created model situations came into existence. Based on practical simulation exercises a lean game training (also called as an experiential method) results in a better learning of theoretical knowledge. The aim of this Master's Thesis is to propose and create simulation exercises i.e. lean game trainings for selected methods of lean manufacturing in automotive companies; to examine the effectiveness of trainings and lean methods and implement them into practice by training employees using lean games. In the theoretical part, selected methods of lean production and lean administration are described. Forms of learning within the enterprise and training methods for employees by implementing Lean Management and Lean tools are also pointed out. The practical part of this Master's Thesis is focused on finding the current status of Lean tools used in the selected company, to find out the knowledge level of employees about Lean tools and Lean Management. Based on the current state, a methodically specific training plan for employees using simulation lean games have been created. In the practical part, simulation lean games suitable for a particular type of production within the enterprise have been also created. Created lean simulation games help employees to learn the practices and methodology of Lean tools in a short time, as well as their use by implementation in the processes. These simulation games can be helpful for all similar production companies or suppliers who want to implement and maintain lean manufacturing processes in the company. Keywords: Lean Management, Lean Methods, Lean games, Trainings within the company, One Piece Flow, Lean Production, training modules