Tools to Establish Focus, Priorities and Objectives

Lean Enterprise Assessment:

This 8 hour company specific course for up to 20 participants will focus on applying a variety of Lean Enterprise Assessment tools and methods to evaluate the current situation and status of the company benchmarked against a variety of lean enterprise criteria. The specific outcomes of this session are a detailed summary of the company position against world class metrics, specific assessment scores in a variety of lean categories, identification of initial problems, issues and opportunities and an initial framework of where to set priorities and focus to move the company forward on a Lean Enterprise Journey.

Establishing Company Goals, Objectives and Priorities:

This 8 hour company specific course for up to 20 participants will define specific goals, objectives and priorities for beginning or continuing a Lean Enterprise journey. Leveraging from the Lean Enterprise Assessment, this session will help create clarity with respect to specific goals, measurable results targets and objectives and define a priority list of actions to begin or continue a Lean Enterprise journey.

Lean Opportunity Analysis:

This 16 hour company specific course for up to 20 participants will develop a specific case for change and define the financial opportunity that exists for beginning or continuing a Lean Enterprise journey. The primary outcome from this training will be to define where and to what level the company could gain financially from their Lean Enterprise journey.

Planning for Success:

This 16 hour company specific course for up to 20 participants will apply tools and methods to establish an implementation plan for beginning or continuing a Lean Enterprise journey. A specific Project Implementation Plan will be developed including all key actions required over a 12 to 24 month period to initiate or continue a Lean Enterprise journey. Project plan tasks, timelines, resource assignments and initial budget will be identified and documented.

Lean Tools Training for Employees and Stakeholders

Custom Lean Simulation Training:

This 8 hour session for up to 30 participants uses a hands on approach to simulate an actual process situation will result in a direct connection between the current state of the operation and how to apply lean tools and techniques to the current situation. Participants will see and learn how to apply lean tools and techniques to a current operational process in a non threatening class room environment, however will see how the application can be implemented in their real world situation. The Custom Lean Simulation Training can be conducted for manufacturing or office environments and processes.

Lean Enterprise Overview Training:

This 8 hour session for up to 30 participants focuses on giving participants a solid understanding of a Lean Enterprise journey. Details covered include the fundamental lean principles, touring their facility to look for and identify waste in processes and systems, discussing and coaching on the cultural aspects of implementing lean, reviewing the importance of solid goals and objectives, discussing the need for a good implementation plan and having specific resources responsible for making lean happen within the organization.

Leading a Lean Initiative Training:

This 8 hour session for up to 30 participants will discuss and teach various methods and techniques required to lead a lean enterprise initiative including the importance of involvement in the planning and implementation events. This session will emphasize that leadership comes from all levels of the organization and will arm participants with tools and techniques necessary to make their lean journey a success.

Lean Implementation Tools Training:

This 8 hour session for up to 30 participants will introduce the primary lean implementation tools and techniques used to drive the improvement on the lean journey. Tools including Value Stream Mapping, Continuous Flow, Pull Systems and Kanban, Standard Work, Line Leveling, 5S and Visual Controls, SMED, Total Productive Maintenance, Error / Mistake Proofing, Lean Metrics and Kaizens for Improvement will be covered in this session.

Value Stream Mapping Training:

This 16 hour session for up to 15 participants will create a specific Value Stream Map of a real example in their company. Participants will map the Current State of the Value Stream, define the Future State of the Value Stream and develop an initial Value Stream Implementation Plan. Results from Value Stream Mapping will include defining the results that can be achieved by implementing the Future State as well as support the start of implementation of the Lean Enterprise journey.

Lean Metrics, Management and Visual Factory Training:

This 8 hour session for up to 20 participants will teach the importance of having operating metric in place to monitor and improve performance, how to use operating metrics to drive continuous improvement and the importance of making metrics and processes visual throughout the plant or operation. Specific lean metrics, charting and posting techniques, morning market meeting processes and recognition techniques will be discussed.

5S Workplace Organization and Improvement Training:

This 8 hour session for up to 20 participants will focus on hands on deployment of the 5S method for workplace improvement. Participants will conduct initial Sorting of work areas, followed by Set-In Order, Shine, Standardize and Sustaining. These sessions are effective when conducted over a number of weeks allowing the organization to establish and practice standards and put measurements in place to support sustaining the gains. Participants will understand how 5S Workplace Organization not only creates a healthier and safer work environment, but will understand that significant wasted time and effort can be eliminated.

Continuous Flow, Pull and Kanban Training:

This 8 hour session for up to 20 participants will focus on applying One Piece Flow, Continuous Flow, Pull and Kanban techniques to a specific work area within a company. The session will help participants learn and understand that the ultimate goal is one piece flow, but were one piece flow is not possible, tools such as Pull Systems and Kanban can provide significant improvement in inventory reduction, inventory management and making sure the right parts are at the right place at the right time to support the customer needs.

Standard Work – Line Redesign Training:

This 8 hour session for up to 20 participants will introduce fundamental standard work analysis and application focused on line redesigns for one piece flow and optimization of productivity within a production line or production cell. Concepts covered include standard work analysis, standard work combination, cell layout and work content distribution within a work cell.

Set Up Time Reduction – SMED Training:

This 8 hour session for up to 20 participants will teach specific tools and methods for evaluating current machine or process set up times, provide techniques to reduce set up time and eliminate all unnecessary waste associated with Set Ups. The ultimate goal for set ups is SMED (Single Digit Minute Exchange of Dies means changing over a machine or process in single minute digits or less than 10 minutes). This session will provide hands on evaluation of a set up and work through various techniques and methods to eliminate the waste and reduce the set up time.

Poke-Yoke Error Proofing Mistake Proofing Training:

This 8 hour session for up to 20 participants will teach basic error proofing and mistake proofing process and techniques to eliminate defects from occurring by eliminating the root cause of the defects. Participants will be exposed to a process to analyze defects, determine the cause of the error creating the defect and then be given the opportunity to apply poke-yoke methods and techniques to the process to eliminate the errors and thus eliminate the defects. Also covered are the 7 Basic Problem Solving Tools used in a Lean Enterprise environment. Participants will be asked to apply each of the tools in real life examples within their companies.

Total Productive Maintenance Training:

This 8 hour session for up to 20 participants will introduce key elements of Total Productive Maintenance including measuring Overall Equipment Effectiveness (OEE), identification and elimination of the Six Big Losses that impact equipment performance and tools and techniques for improving equipment performance. Participants will discuss how TPM impacts wastes including over processing, inventory, waiting and overproduction and how to address those wastes.

Project Management Training:

This 8 hour session for up to 20 participants consists of discussion and hands-on exercises. Participants will examine the concepts of project management and introduce tools and skills necessary to plan, manage and deliver successful projects.  From initial planning to final review, learn how to set measurable objectives, estimate time requirements, design schedules, control costs, and manage relationships across the spectrum of project stakeholders.  The practical approach of this course gives participants a model that allows them to apply course content to real workplace situations.

Lean Implementation Workshops and Train the Trainer

Value Stream Mapping Workshops:

This 24 hour, 3 day workshop for up to 15 participants teaches how to complete a Value Stream Map including Current State, Future State and Detailed Implementation Plan to achieve the future state using your company specific value stream. This course provides the fundamental framework and plan for beginning or continuing your companies Lean Enterprise journey. Participants will identify waste in the current value stream and apply lean tools and techniques to eliminate that waste in the future state value stream map design. The outcome of this workshop is a practical action oriented plan that can be achieved in a 1 to 12 month timeframe.

Kaizen Implementation Workshops:

These 1 to 5 day workshops for up to 15 participants provide the action oriented hands on implementation of lean tools, techniques and methods to achieve the future state as defined by a value stream map or simply to address a specific process improvement need. Leading into the workshop, a specific set of goals and deliverables will be established to support measuring specific gains and improvements. Kaizen Implementation Workshops can be conducted on, but are not limited to the following:

• 5S Workplace Organization
• Production Line or Cell Design or Redesign
• Establishing Continuous Flow
• Plant Layout Designs or Implementation
• Pull Systems and Kanban Implementation
• Set Up Time Reduction / SMED Application
• Poke-Yoke – Error and Mistake Proofing
• Lead Time Reduction
• Inventory Reduction
• Establishing Lean Metrics and Management Practices
• Total Productive Maintenance
• Process Improvement

Advanced Project Management Workshops:

In these 2 day workshops participants concentrate on refining plans and integrating the project into the organization.  Building on the foundation of “Project Management”, they revisit specific areas in the project management process and focus on key issues that are critical to the project’s outcome.  Common mistakes, oversights, and pitfalls in the project management process are also considered. Participants should bring a current or potential project concept to use during exercises and activities. 

Kaizen Implementation Train the Trainer Certification:

This comprehensive 3 to 4 month program consists of teaching key individuals within your company how to scan, plan for, conduct and follow up Kaizen Implementation Workshops. It is designed as a hands-on, developmental process that will pair two individuals within your company and take them through a series of Kaizen Implementation Events culminating in them being able to conduct events on their own without the need of external resources. Participants will learn the process steps in conducting kaizen events and will co-lead and ultimately lead events on their own. To complete certification participants must attend a three day kaizen event, co-lead a three day kaizen event and fully lead a three day kaizen event on their ownTypical improvement results from the kaizen events conducted are achieved. Each participant receives individual feedback on their performance with respect to conducting kaizen events.

Lean Enterprise Train the Trainer Certification:

This comprehensive 6 to 8 month program consists of developing key individuals within your company in the understanding and successful hands-on application f Lean Enterprise tools, techniques and methods. It is designed as a combination of class room and practical application activities focused on having the participants demonstrate the ability to comprehend, apply and achieve results by applying lean enterprise tools, techniques and methods. Candidates and their company sponsors will be paired with another certification candidate and be teamed with another company team to expand their exposure of applying lean in various environments. To complete certification, participants must participate in all classroom training and demonstrate their abilities to apply a variety of assessment tools, planning tools, implementation tools and complete a project that will deliver a minimum of $50,000 in sustainable annual savings.

Other Customized Lean Training Programs are available including but not limited to:

• Accelerated Lead Time
• Coaching for Lean Performance
• Introduction to Six Sigma
• Solving Quality Problems
• Sustaining Momentum for Continuous Improvement
• Teamwork in the Lean Environment
• Total Productive Maintenance Basics
• Hoshin Planning
• Supply Chain Fundamentals

Questions?  Please Contact Us.