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IMPROVE PROCESS EFFICIENCIES: Lean Manufacturing Overview with Simulation – Metro East

November 1, 2022 @ 8:00 am - 4:00 pm


Meeting today’s manufacturing challenges demands a lean enterprise — streamlining product design and manufacturing by applying lean manufacturing principles, concepts and techniques. The primary focus of this effort is the continuous elimination of waste in the company’s business processes. Implementing Lean practices involves changing a work area or a business process to maximize efficiency, improve quality and safety, eliminate unnecessary motion and inventory, and save time and resources.


This interactive workshop combines comprehensive classroom instruction with simulation of a production facility. The basic concepts of Lean manufacturing and the tools and methodology necessary to implement “lean” on the shop floor are demonstrated. Participants assume the role of production workers, applying lean tools to their individual workspaces and the entire product line. This learn-do technique, over three “shifts”, illustrates cause and effect relationships for each of the lean tools presented.

Participants review methodology and lessons learned from previous shifts, deciding what and how to implement while working with realistic constraints such as available resources, cash flow, and resistance to change.


Following the Lean Manufacturing Overview and Simulation, participants will have learned several new techniques to aid you in the Lean transformation on-site. You’ll be able to:

  • Differentiate between a “push” and a “pull” system
  • Identify the eight (8) wastes that must be eliminated to make the manufacturing processes Lean
  • Explain how those wastes reduce company profits
  • Understand the functions of a Kanban system
  • Make more effective use of the employee’s time following waste elimination


  • 8:00 AM -Traditional Manufacturing & 8 Wastes
  • 9:00AM – Round 1 – Traditional Manufacturing Simulation Workplace Organization (5S)
  • 10:00AM – 5S System, Visual Controls, Standardized Work, Plant Layout, Point of Use Storage, Batch Size Reduction, Quick Changeover
  • 11:30AM – Round 2 – Applying Basic Lean Tools
  • 12:00PM – Break – Lunch
  • 12:30PM – Teams, Quality at the Source, Cellular Manufacturing, Pull Systems, Total Productive Maintenance
  • 2:00PM – Round 3 – Applying Intermediate Lean Tools
  • 3:00PM – Wrap-up


Greg Thompson | Technical Specialist, IMEC

Greg worked for over 10 years in the semiconductor and food manufacturing industries prior to joining IMEC. He held positions in Industrial Engineering, Operations Finance, & Supply Chain Planning. He has worked for IMEC for over 15 years, focusing on continuous improvement and lean manufacturing training and implementation. He attended the University of Illinois (U-C), earning a BS & MS in Industrial Engineering and an MBA.


Jeremy Smith | Technical Specialist, IMEC

With more than 10 years of manufacturing and management experience in complex automotive electronics supplemented by an engineering B.S. from the University of Illinois, Jeremy has a variety of skills and knowledge that he uses to enable success. Working with and in teams across business divisions and multiple countries has provided a wide perspective on how to achieve goals and provided a clear picture that everyone wants to succeed. His goal is to apply the right tools in the right way at the right time to enable that success.


Presented in Partnership with:

IME IMA logo






Cancellations made within seven (7) days of the program start date, or failure to inform IMEC of cancellation may result in up to 50% of the invoiced attendance fee.

Cost: $350

Contact Name: Camryn Tunney

Contact Email: ctunney@imec.org