We Build Lean

TOWTRUCKS

Vol. I

Vol. II Vol. III

Vol. III

4Lean Catalog Vol.III M

ISUALanagement

V

M

4SAFETYLean

Office CastersXX

-TRUCKS

System

Lean4

IZENAREAK

System

Lean4

LIFTS &

ccessories 4Le n A

Revision nº.040 05-06-2018

| Revisão | Rivisione | Revisión | Révision

Index

Volume 1

4Lean System 4

Aluminium System 46

Aluminium System + 65

4Lean System + 77

4Lean Mockup 99

4Lean Accessories 105

Dexion – Racks 126

Kaizen Area 134

D-Trucks 137

Lifts & Trucks 139

4.0 Lean 147

XPannels 156

Volume 2

MWagon 4

Visual Management 22

4Safety 133

XContainers 148

XCasters 166

Xrolls 180

Lean Office 191

Volume 3

Lean Games 4

4Lean School 8

|Índice | Indice | Índice | Index

4Lean is a company dedicated to the creation and implementation of Lean

solutions. We have a vast knowledge in Lean, we are able to implement a full supply

chain with our vast portfolio that is developed in our Lean Lab.

All organization practice Lean everyday. We have regular training in Lean and we

participate in Kaizen Events to understand customer needs.

We believe our gemba is at customer site, we are a natural extension of your

organization.

4Lean é uma empresa dedicada à criação e implementação de soluções Lean. Temos um vasto conhecimento em Lean,

somos capazes de implementar uma cadeia de fornecimento completa com o nosso vasto portfólio que é desenvolvido no nosso Laboratório Lean. Todos na organização praticam Lean diariamente. Temos uma formação regular em Lean e participamos em eventos Kaizen para entender as necessidades dos clientes. Acreditamos que o nosso gemba está à vista do cliente, somos uma extensão natural da sua organização.

4Lean è una società dedicata alla creazione e implementazione di soluzioni di Lean. Abbiamo una vasta conoscenza in Lean e siamo in grado di implementare una catena di approvvigionamento grazie alla nostra vasta gamma sviluppata nel nostro Lean Lab. Tutta la nostra organizzazione, pratica Lean tutti giorni . Abbiamo formazione regolare in Lean e partecipiamo a cantieri Kaizen, eventi per capire al meglio i nostri clienti. Crediamo che il nostro gemba è presso il cliente, siamo una naturale estensione della vostra organizzazione.

4Lean es una empresa dedicada a la creación e implementación de soluciones de Lean. Contamos con un amplio conocimiento en Lean, somos capaces de implementar una cadena de suministro completa con nuestro amplio catalogo que se desarrolla en nuestro Laboratorio de Lean. Todos en la organización practicam Lean diariamente. Tenemos una formación regular en Lean y participamos en Kaizen Eventos para entender las necesidades del cliente. Creemos que nuestra gemba está en el sitio del cliente, somos una extensión natural de su organización.

4Lean est une société dédiée à la création et la mise en œuvre de solutions Lean. Nous avons une vaste connaissance dans Lean, nous sommes capable de construire une chaîne d'approvisionnement complète avec notre vaste portefeuille qui est développée dans notre Lean Lab. Tout l’organisation pratique Lean quotidienne. Nous avons régulièrement des formations Lean, nous participons à chantier Kaizen pour comprendre les besoins des clients. Nous croyons que notre gemba est le site du client, nous sommes un prolongement naturel de votre organisation

About us

We Build Lean !

4

Lean Games

5

Training Kits | Kits de formação | Kits di formazione| Kits de formación | Kits de formation |

Reference Referência/

Articolo Referencia/ Référence

Training Formação /

Formazione / Formación /

Entraînement

Contents Conteúdo / Contenuto / Contenio / Contenu

Picture Imagem /

Immagine / Imagen / Image

TK-5S 5S’s and Visual

Managment

• Visual management;

• Standards;

• SDCA/PDCA;

• 5S;

• Muda.

TK-SMED SMED

• SMED’s steps;

• Standard method;

• Internal & External work;

• Convert internal work in internal;

• Reduce time of internal work.

TK-FL Flow

• Waste vs. Value

• Standard work

• Yamazumi

• 5S

• PDCA

TK-PS Problem Solving

• 5s & Is not;

• Root cause;

• Ishikawa diagram;

• Poka-yoke;

• Standards;

• SDCA/PDCA;

• DMAIC.

6

Dojo Equipments | Equipamentos Dojo | Attrezzature Dojo | Equipamiento Dojo | Équipements Dojo |

Flow Small Parts

Content Dojo Small Parts

Takt time

Yamazumi – Line balance

Kanban

Supermarket

Mizusumashi – Logistic Train

Heijunka – Line balance

Standard work

Borderof the line

Pull System

Dojo Small Parts

Content Conteúdo / Contenuti / Contenido / Contenu

Takt time

Yamazumi – Line Balance

Kanban

Supermarket

Mizusumashi

Heijunka – Line Balance

Standard work

Border of the line

Pull System

Reference Referência/ Articolo

Referencia/ Référence

Dojo Equipments | Equipamentos Dojo |

Attrezzature Dojo | Equipamiento Dojo | Équipements Dojo |

Contents Conteúdo / Contenuto / Contenio / Contenu

DE-SP Small Parts

• Takt Time

• Yamazumi – Line Balance

• Kanban

• Supermarket

• Mizusumashi – Logistic

Train

• Heijunka – Line Balance

• Standard work

• Border of the line

7

Lean Posters

Lean Posters Lonas Lean / Lean Poster / Lean

Posters / Lean Posters

Dimensions (mm) Dimensões / Dimensioni / Dimensiones / Dimensions

Female Strike Zone 1580(L) x 550(W) x 1990(H)

Male Strike Zone 1580(L) x 550(W) x 1990(H)

Golden Zone 1660(L) x 910(W) x 930(H)

SMED

Content Conteúdo / Contenuti / Contenido / Contenu

SMED Steps Etapas SMED / SMED Passi / SMED Pasos / SMED Étapes

Standard method Método padrão / Metodo standardizzato / Método estándar / Méthode standard

Internal & External Activities Actividades interna e externa / Attività interna ed esterna / Actividades internos y

externos / Activités internes et externes

Convert internal activities to external Converter atividades internas para externas / Convertire attività interne per esterne /

Convertir actividades internas a externas / Convertir activités internes à externes

Reduce internal and external activities Reduzir atividades internas e externas / Ridurre le attività interne ed esterne / Reducir

las actividades internas y externas / Réduire les activités internes et externes

Flow Fluxo / Flusso / Flujo / Flux

Content Conteúdo / Contenuti / Contenido / Contenu

Value and waste Valor e desperdício / Valore e rifiuti / Valor y desperdicio / Valeur et des déchets

Yamazumi

PDCA

Standard work Trabalho normalizado / Lavoro standard / Trabajo estándar / Travail standard

5S

| Lonas Lean| Lean Poster | Lean Posters | Lean Posters |

Goals

Aid project and design of workstations

Workstations ergonomics

Golden Zone

Female Strike Zone Male Strike Zone

* L : Lenght, W – Width, H : Height

8

School

Training Workshops

4Lean School

9

Training and Workshops

Training

Assembly Training

4Lean System

4Lean System +

4Lean Aluminium

4Lean MockUp

Solution Training

Design Training

Workstations

Logistic Trains

Supermarkets

Warehouse

External Logistics

Lean Management

Workshops

Lean Projects

Kaizen Events

Retrofit Events

4Lean Truck

10

Lean Builder

Lean Technician

Lean Engineer

Designs a complete supply

chain flow to reduce waste

Design Guide Training

Ability to coordinate a Kaizen Area

Solutions Guide Training

Ability to build lean solutions

Assembly Guide Training

Certification

Training

11

Available

8 Hours (Per product family)

Process engineers, Lean engineers, Times & methods

Ergonomy Defects

Productivity Cost

Impact areas

Assembly Training

Tra

inin

g: L

ean

Bu

ilde

r

Ergonomy Cost

Productivity Defects

Impact areas

Goals Understand how to build safe structures

Understand how to assemble parts

Content

Assembly Guide:

Tips

Safety Building

Necessary Tools

12 8 Hours

Process engineers, Lean engineers, Times & methods

Ergonomy Cost

Productivity

Impact areas

Solution Training T

rain

ing: L

ean

Te

chn

icia

n

Goals

Understand ways to optimize workstations

Understand how to optimize material handling in all the Supply Chain

Content

Line Feeding

Kanban

Junjo Sequence

Junjo Kit

Handling Units

Workstation Optimization

Types of Production (Small Parts, Machine, Large Parts)

Tools

Hardware

Strike Zone

Golden Zone

Logistic Trains

Types of wagons

Wagon Challenges (Drift, Drag, Stability)

Supermarkets

Boxes

Trolleys

Containers

Warehouse and External Logistics

How to integrate them in logistic trains concept

13

8 Hours

Design Training: Workstations

Process engineers, Lean engineers, Times & methods

Tra

inin

g: L

ean

En

gin

eer

Impact areas

Goals

Project and design of workstations

Workstations ergonomics

Content

Workstations design

Border of the line design

Mockup

Ergonomics

Strike zone

Golden zone

Structural dimensioning

Ergonomy Cost

Productivity Defects

14

8 Hours

Process engineers, Lean engineers, Times & methods, Logistic Engineers

Content

– Logistic trains design

– Casters configuration

– Weight distribution

– Drift, Stability and Drag

– Mock up

Design Training: Logistic trains T

rain

ing: L

ean

En

gin

eer

Impact areas

Goals

Project and design of logistic trains

Logistic trains ergonomy

Understand the different types of logistic trains advantages and disadvantages

Content

Types of logistic trains

Casters configuration

Structure Design

Drift, Stability and Drag

Mock up

Ergonomy Cost

Productivity Defects

15

8 Hours

Design Training: Supermarkets

10 mm

100-2

00 m

m

20 mm 10 mm

Process engineers, Lean engineers, Times & methods, Logistic Engineers

Tra

inin

g: L

ean

En

gin

eer

Impact areas

Goals

Project and design of supermarket

Supermarkets ergonomy

Understand the different types of supermarkets

Content

Types of supermarkets

Strike zone

Picking area

Structure Design

Mock up

Ergonomy Cost Stock

Productivity Defects

16

8 Hours

Design Training: Warehouse

Process engineers, Lean engineers, Times & methods, Logistic Engineers

Tra

inin

g: L

ean

En

gin

eer

Impact areas

Goals

Project and design of racking and storage solutions

Content

Types of racking system

Low cost solution

Types of handling equipment

Hand Picking

Types of Handling Units

Ergonomy Cost Stock

Productivity Defects

17

8 Hours

Design Training: External logistics

Process engineers, Lean engineers, Times & methods, Logistic Engineers

Tra

inin

g: L

ean

En

gin

eer

Impact areas

Goals

Project and design of logistics solutions

Content

Types of trucks

Milk runs

Combining internal/external logistics

Packaging solutions

Ergonomy Cost Stock

Productivity Defects

18

8 Hours

Design Training: Lean Management

Process engineers, Lean engineers, Times & methods, Logistic Engineers, Lean Office Facilitators

Tra

inin

g: L

ean

En

gin

eer

Impact areas

Goals

Project and design of Kanban boards, sequencers and heijunkas

Project and design daily kaizen boards

How to improve 5S

Content

Kanban

Heijunka

Kanban board

Sequencer

Production Boards

Andons

Quality workstations

Ergonomy Cost Stock

Productivity Defects

19

4 Hours

Design Training: 4LEAN CAD

Process engineers, Lean engineers, Times & methods, Logistic Engineers, Designers

Tra

inin

g: L

ean

En

gin

eer

Impact areas

Goals

Draw solutions with 4Lean

components

Content

How to draw 4Lean strucutures

4Lean components

Custom components

Smart dimensions

Delivery Cost

Productivity Defects

20

4 Hours

Design Training: 4LEAN CAD Advance

Process engineers, Lean engineers, Times & methods, Logistic Engineers, Designers

Tra

inin

g: L

ean

En

gin

eer

Impact areas

Goals

Draw solutions with 4Lean

Components

BOM

Work Preparation

Content

How to draw 4Lean strucutures

4Lean components

Triball

Custom components

Linear Dimensions

BOM

Delivery Cost

Productivity Defects

21

4Lean Inspection

Lean Engineer: Specialist in structures assembly;

Performs Safety analysis;

Check critical parts;

Knowledge in Structures design.

22

Lean Projects W

ork

sho

ps - L

ean

Pro

jects

1-2 Days

Process engineers, Lean engineers, Times & methods

Future State

Breakthrough solutions focused on global waste reduction

Analyse current state and deliver solutions

23

Kaizen Events

5 Days

Process engineers, Lean engineers, Times & methods

Mockup Process Final Solution

Wo

rksho

ps - K

aiz

en

Even

ts

To help our customers to implement Lean, participating or leading Kaizen Events

24

Retrofit Events W

ork

sho

ps - R

etro

fit Even

ts

5 Days

Process engineers, Lean engineers, Times & methods

Turning old into new, transforming what exists into useful structures adequate to the new reality

25

4Lean Truck

1-5 Days

Process engineers, Lean engineers, Times & methods

Wo

rksho

ps –

4L

ea

n T

ruck

4Lean Truck is the most effective solution when complex applications must be implemented very quickly

Your company makes the request and we take care of the rest

Our assembly team, travels to your company and assemble the applications in your manufacturing environment

26

Notes

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•

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| Notas | Appunti | Notes

27

Italy

Iberi

a

DE

U

K

Porto

Stutgart

Bilbao

Bergamo

Liverpool

4Lean in Europe

28

4Lean, Lda

4lean@4lean.net www.4lean.net

We Build Lean

| Alguns dos nossos clientes | Alcuni dei nuostri clienti | Algunos de nuestros clientes |

Certains de nos clients

Some of our clients