Using Kanban/JIT Systems and Lean Elements to Run a Startup Plant

Instructor: Jose Mora
Product ID: 700419
Training Level: Intermediate
  • Duration: 90 Min

recorded version

1x Person - Unlimited viewing for 6 Months
(For multiple locations contact Customer Care)
Recorded Link and Ref. material will be available in My CO Section

Training CD

One CD is for usage in one location only.
(For multiple locations contact Customer Care)
CD and Ref. material will be shipped within 15 business days

Customer Care

Fax: +1-650-963-2556


Read Frequently Asked Questions

This training program is essential for those introducing lean principles at the company’s earliest stages. A startup plant faces many challenges and options. Too often, the brainpower and focus is on the science and technology of the product. However, without agile systems from the earliest stages, the company may struggle for the wrong reasons as it tries to ramp up its manufacturing and quality systems.

Why Should You Attend:

This webinar will explain how to set up and use kanbans all the way from purchasing and procurement, to receiving, receiving inspection, component stock, work order picking/staging, assembly, packaging, finished goods, and sterilization. Combining the principles of a visual workplace with kanban bins and cards, this webinar will demonstrate step-by-step how to create a demand-pull system to achieve the right balance of inventory and throughput throughout your startup operation. The hands-on use of Drum-Buffer-Rope from Theory of Constraints (TOC) will also be covered.

Lean cannot be just about product and process. Based on the speaker’s extensive experience in the arena, this webinar will also discuss the elements of lean documents and lean configuration, since the principles of lean must permeate throughout all systems, not just the manufacturing supply chain.

Learning Objectives:

  • Myths about lot size and local efficiencies.
  • Myths about documentation and support systems.
  • An alternative way to track yield losses during product builds.
  • Preparing kanban cards and bins to control both in-house inventory and external supplier inventory.
  • Smart ways to track variable information using kanban cards (example lot number, PO number, WO number, due dates).
  • How to use kanbans for R&D prototype work?
  • How to simplify paperwork to allow smaller lot sizes?
  • Smart ways to simplify receiving verification.
  • How product shipments trigger new builds?

Areas Covered in the Webinar:

  • Working definitions of kanban, JIT, pull system, and Drum-Buffer-Rope, with emphasis on medical device and biotechnology manufacturing.
  • Introduction to the elements of lean documents and lean configuration.
  • Selection of appropriate sterilization lot size - a key factor.
  • Practical lot sizes for start-up medical devices.
  • How to handle large-volume and offshore suppliers?
  • How MRP II can help - and hinder - an effective kanban system?
  • How to use kanbans to track off-site sterilization services?
  • Using kanbans with external supply chain suppliers.
  • Smart ways to minimize lot picking times.
  • Lot picking inside a cleanroom

Who Will Benefit:

  • Project Leaders
  • Functional Managers
  • Manufacturing Engineers
  • QA Managers
  • Operations Managers
  • Supply Chain Managers
  • Purchasing Managers
  • Design Engineers
  • Design Assurance

Instructor Profile:

José Mora is a principal consultant specializing in manufacturing engineering and quality systems. For over 30 years he has worked in the medical device and life sciences industry specializing in manufacturing, process development, tooling, and quality systems. Prior to working full time as a consulting partner for Atzari Consulting, Mr. Mora served as director of manufacturing engineering at Boston Scientific and as quality systems manager at Stryker Orthopedics, where he introduced process performance, problem solving, and quality system methodologies. During that time he prepared a white paper on the application of lean manufacturing methods to the creation and management of controlled documents and a template for strategic deployment.

Mr. Mora led the launch of manufacturing at a start-up urology products company as director of manufacturing for UroSurge, Inc. at the University of Iowa’s business incubator park in Coralville, IA, creating a world-class medical device manufacturing operation, with JIT, kanban systems, visual workplace and lean manufacturing practices. Mr. Mora worked for 10 years at Cordis Corporation, now a Johnson & Johnson company, where he led the successful tooling, process development and qualification of Cordis’ first PTA (percutaneous transluminal angioplasty) catheter. His medical device experience includes surgical instruments, PTA & PTCA dilatation and guiding catheters, plastic surgery implants and tissue expanders, urology implants and devices for the treatment of incontinence, delivery systems for brachytherapy, orthopaedic implants and instruments, and vascular surgery grafts and textiles. During his time at Cordis, he managed the maintenance and facilities department, taking that operation to a level rated as “tops” by the UK Department of Health and Social Services (DHSS) during one of their intensive audits.

Mr. Mora managed Manufacturing Engineering as part of the Guiding Catheter core team of managers, a team that took the Cordis Guiding Catheter business to lead the market, bringing it up from fourth place. By introducing world-class techniques, the Guiding Catheter design and manufacturing was completely re-engineered for robust design and tooling, under Mr. Mora’s leadership. He was also instrumental and played a leadership role in the complete re-engineering of the Tooling Control System, including design drafting, the tool shop and technical support. Wherever he has worked, he has a track record of introducing world-class methodologies such as Kepner-Tregoe, Taguchi techniques, Theory of Constraints, Lean Manufacturing, Five S (Visual Workplace), process validation to Global Harmonization Task Force standards, and similar approaches.

Topic Background:

A medical device or biotechnology startup plant needs to have product available yet be agile enough to respond quickly to demand and design changes without wasting excess inventory, especially from obsolete products that did not pan out.

Follow us :
ComplianceOnline Banking Summit 2016 | Risk Management and Data Security - 80390SEM
21 CFR Part 11 Compliance for SaaS/Cloud Applications - 80202SEM

Product Reviews

This product hasn't received any reviews yet. Be the first to review this product! Write review

Best Sellers
You Recently Viewed