Mixed Model Line Design Workshop

Hosted at Toyota Material Handling
Columbus, Indiana

$1,995 per seat
Register by July 6, 2018 to save $300 per seat.

There are no up-coming events

Is this workshop right for you?

Schedule a Free Consultation

This workshop includes factory tours of Toyota Material Handling, the #1 manufacturer of fork trucks in North America and winner of Assembly Magazine's Plant of the Year Award in 2011. See the concepts you learn in class put to action right before your eyes! As a special bonus, Toyota managers will also conduct additional Q&A sessions after the tours.


Take the leap beyond 5S, Value Stream Mapping and SMED to where the real process improvements take place: Lean Process Design. The future of manufacturing belongs to multi-product manufacturing, but few Lean practitioners are competent in mixed model line design. A large majority of the benefits of a Lean Transformation come from improved Process Design, and there is a step-by-step methodology that will lead to an optimum value-stream design.


20%+ boost in productivity.

20%+ boost in productivity.

Higher level of operator engagement.

Higher level of operator engagement.

Shorter lead times.

Shorter lead times.

Leveled product volumes.

Leveled product volumes.

Increased flexibility in responding to changes in the market.

Increased flexibility in responding to changes in the market.

Free up floor space, your most expensive manufacturing real estate.

Free up floor space, your most expensive manufacturing real estate.


"Very well organized. Good content distribution. Good sequencing. I see a lot of value in practical exercises."
— Natalia, Creation Technologies

"The class was a great introduction in line design. It was incredibly thorough. I will recommend this class to my peers."
— Marzel, W Machine Works

"Very different way to look at Takt time!! I've always heard Takt for product. Takt for process opens up a whole new world of possibilities."
— Dan, Henny Penny

Who Should Participate?

This workshop is for anyone responsible for designing, implementing, or managing a Mixed Model production line based on Lean principles.

  • Manufacturing Engineers
  • Managers
  • Supervisors
  • Material Professionals
  • Supply-Chain Professionals

Day 1

Introduction to the Roadmap

A roadmap is a form of Standard Work for line design. This will give you the ability to improve your line design approach over time, moving towards perfection.

Mixing Products

Mixing products has a host of advantages including better lead times, increased flexibility, more efficient use of floor space, and leveled product volumes.

Process Flow Diagrams

As you define processes, identifying and documenting all those resources is strongly recommended, as you will be calculating the number of all those resources when it comes time to design the line.

Process Flow Matrix

One Process Flow Diagram does not provide enough information to make well-informed decisions on the whole line, so you must find a way to extract applicable information.

Takt Time and Takt Volume Modifiers

For your Mixed Model line, Takt is the line’s formulated production rate. This rate is calculated and is a design parameter for the line.

Effective Work Time

How much time do operators actually spend working? This is an important factor for accurate calculations.

Day 2

Standard Work

We'll also teach you how to create and use Standard Work Definitions based on the format we've polished over 20+ years of Lean consulting experience.

Resource Calculations

A process may have more than one type of resource associated with it. It is very common for a process to require Labor resources as well as Machine resources.

Workstation Definition

How do you calculate the number of necessary workstations? The resource calculation is your starting point for this step, but you need to know how to interpret the calculations.

In-Process Kanban

By allowing an extra unit, an IPK provides one Takt Time of buffer. This will help to smooth out the imbalances that result from varying human work pace, and from the variable work content of different products.

Integrating Machines into the Design

Machines should be integrated directly into your line design as much as possible, but there are some challenges that you might need to overcome when dealing with machine resources.

Applying the Balancing Tools

Different tools apply to different situations, and the relocation of work applies primarily to labor-driven processes. In this lesson we will cover when and how to use six balancing tools: Eliminate Waste, Relocate Work, In-Process Kanbans, Add Resources, Time Plus Inventory, and Sequencing.

Day 3

Overcoming Changeovers

Our goal in this lesson is to calculate the optimum batch size that the machine has to build, in order to overcome changeovers and not build up too much inventory.

Conceptual Layout

This is your chance to figure out how the underpinnings of your line will work. How is it going to look? A Straight line? Bend at workstation 4? U-Shaped maybe? If there are batch processes, how would those operate in this line?

Creating a Deployment Plan

As a line designer, you have a long list of things to consider now. There will be equipment, facilities, tools, fixtures, pilot runs, tweak this, tweak that, and then tweak them both again.

Simulation Modeling

What data do you need to collect to build an accurate Simulation Model?

Creating a Company-Specific Action Plan

Our goal at the end of the workshop is that every company will have an action plan for an immediate improvement at their home factory.

Next Steps

What can you do to make the greatest improvements at your factory going forward?

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