Advanced Mixed Model Manufacturing Workshop [Postponed]

Hosted at Toyota Material Handling

$1,995 per seat

Seating is limited to a capacity of 32 students.

What You Will Learn at This Workshop

The Advanced Mixed Model Workshop is a deep dive into complex subjects including Simulation, Sequencing, In-Process Kanbans, and Line Design Validation. For each subject you will be using our custom simulation software to conduct simulation-based experiments.

Our goal is to develop a high level of expertise in the line design skills that are most often missing including the use of simulation software, the development of sequencing rules, the optimizing of buffer sizes, proving the benefits of flexing, and optimizing the performance of your mixed model line.

This is an extremely hands-on workshop, and your new skills will be immediately transferable to your company!

Why Toyota Material Handling?

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. Here’s what Assembly Magazine had to say about Toyota Material Handling.

Toyota has long been regarded as the gold standard for Lean manufacturing. You will see many methods that we teach in-action on the factory floor.


Simulation software

Learn how to develop simulation models and, arguably more importantly, how to analyze your results so that you can make necessary adjustments.

Identify flow bottlenecks

Zero in like a laser beam on potential bottlenecks and constraints in line performance, by easily modeling the line.

Creating sequencing rules

The order of your production schedule (sequence) can make a huge difference in line performance. We'll show you how to create and test optimum sequencing rules.

Demonstrate flexing

Understaffing the line and having workers "flex" can give you a 30% productivity jump! Use a simulation model to test and sell the concept.

Establish optimum buffers

The careful use of buffers (IPKs) can improve throughput dramatically. In this course we will explain how to optimize your use of buffers.

Embrace a new kaizen tool

Incorporate simulation modeling into your ongoing Kaizen program, and boost your Kaizen Event results.

Who Should Participate?

This workshop has been designed for anyone responsible for designing, implementing, or managing a Mixed Model production line. 

  • Manufacturing Engineers (MEs)
  • Industrial Engineers (IEs)
  • Process Improvement or Lean Specialists
  • Operations Managers and Supervisors

Workshop Schedule

Day 1

The Mixed Model Line Design Roadmap is Standard Work for line design. The course will start with a review of the methodology. Take the online Mixed Model Line Design course if necessary.

In this lesson we will map the Mixed Model methodology against the data requirements of a simulation model. What is already there, and what is missing?

In this lesson we will explore the various sources of variability that have a negative impact on flow and throughput. All of these are visible and addressable in your simulation software: human variability, process variability, product work content variability, sequencing variability.

At the heart of the scientific method is the process of running experiments and analyzing the results. In this lesson we will learn how to interpret simulation results, in order to know where improvements are needed.

Before you can conduct experiments or make changes, you need to have a model that works! In this portion of the course you will build a model and get it working.

Day 2

In this lesson you will learn what “sequencing” is, why it is critical for a high-performing line, and what some of the common sequencing rules are.

Working in small teams, you will develop a set of sequencing rules using your simulation model. Teams will compete to create the best set of rules, and present their results to the class.

Using “buffers” or allowing additional inventory in the flow is a powerful and relatively inexpensive way to boost line performance. In this lesson we will review how buffers work, why the “law of diminishing returns” manifests quickly, where in the flow buffers are needed, and how to establish the number of pieces allowed between workstations or processes.

Again working in teams, you will run a series of experiments on the use of buffers and their impact on throughput. The deliverable from this exercise will be an In Process Kanban plan, with locations and number of buffer pieces needed.

Day 3

The deliberate under-staffing of a production line is one of the golden keys to advanced productivity. Workers will move to where the work needs to be done following visual signals, and this movement is called “flexing”. Flexing remains one of the biggest opportunities for productivity improvement, in the double digits!

Each team will be tasked with the creation of a line design that can not only support the necessary production volumes, but can also support a flexing strategy where there are more workstations than workers. Some line redesign will be needed. Teams will report-out on their changes to the original line design.

The application of AMMLD techniques learned in this workshop will probably need to be implemented in pieces, and not all at once. In this lesson we will cover the use of AMMLD and simulation software as an integral part of an ongoing Kaizen effort.

Each team will be allowed 1 hour to make any further changes and improvements to their line design, in order to optimize throughput, productivity, and flexibility. The instructor will then give them a new production sequence for them to run and document. Finally, each team will deliver a PowerPoint presentation (template provided) documenting all of the improvements made to the original baseline model created on Day 1. May the best team win!

Upcoming Workshops

Advanced Mixed Model Manufacturing

May 5 – 7, 2020
at Toyota Material Handling

This event is being postponed due to the coronavirus outbreak. Many companies are restricting travel, and reducing public interactions is recommended at this time. We will reschedule this workshop at the next appropriate opportunity.

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