LEAN THINKING – ENLIGHTENMENT

1A Lean Conversion Overview
(Formats 1,2,3,*)

An overview of Lean Conversion concepts and introduction to methods and tools designed to put these concepts to work for you. Participants will also learn the 8 types of waste and how to eliminate them through the Lean “Building Blocks”. Brief discussion on topics such as workplace organization (5S), quick changeover, total productive maintenance, visual workplace, cellular design, and Poka-Yoke.

1B Hands-on Lean Simulation
(Formats 1,2,3,*)

An introduction to Lean Conversion concepts, methods, and tools while simulating a factory to put these concepts to work for you. Participants will also learn the 8 types of waste and how to eliminate them through the Lean “Building Blocks”. We will discuss and implement various tools such as workplace organization (5S), quick changeover, total productive maintenance, visual workplace, cellular design, and poka-yoke. This workshop will help you understand Lean conversion principles and the benefits of Lean.

2 Value Stream Mapping (VSM)
(Formats 1,2,3,*)

Hands-on introduction to Value Stream Mapping to “see the flow” and create future state value streams. Participants will learn the fundamentals of identifying and managing the value stream.

Recommended Prerequisites: 1

3 Lean Cultural Transformation
(Formats 1,2,3,*)

Introduction to the methods and techniques that manage cultural change. This course will address the impact that implementing Lean practices can have on people in the workplace and outlines methods you can use to establish a positive culture.

Recommended Prerequisites: 1-2

LEAN THINKING – DEVELOPMENT

Kaizen is continuous improvement, reflected by ongoing, incremental, small-scale changes that have positive impact. Participants will learn the process for developing a continuous improvement plan for reducing waste and cutting cost while increasing customer satisfaction.

Recommended Prerequisites: 1-3

Detailed training in the 5S techniques of Sort, Straighten, Shine, Standardize, and Sustain. Participants will be given specific strategies for making sustainable improvements in their workplace for immediate implementation.

Recommended Prerequisites: 1-4

This course will provide participants with an understanding of the Kanban/pull concept as it applies to both paperwork flow and material control processes. Participants will learn why a pull system is important, discuss various types of Kanban and identify which Kanban type to use in their organizations.

Recommended Prerequisites: 1-5

LEAN THINKING – DEPLOYMENT

Participants will learn how to get people and machines to work together as efficiently as possible to reduce lead times, minimize work-in-process, optimize floor-space usage, and improve productivity. Hands-on demonstration on how implementing Work Cells will help you achieve waste reduction in terms of time, travel, and most importantly -- inventory.

Recommended Prerequisites: 1-6

Participants will learn the techniques used to reduce set-up times on equipment and machinery, in front office processing, and within service organizations. Using real-life examples, case studies, and hands-on quick changeover analysis, this class provides the practical tools and methods needed to radically reduce changeover time in the office or on the shop floor.

Recommended Prerequisites: 1-6

Participants learn how to successfully transform a factory into a well-organized workplace where thousands of messages concerning product quality, productivity, schedule, and safety are accurately delivered every day.

Recommended Prerequisites: 1-6

Participants become familiar with TPM, a systematic approach for minimizing machine downtime resulting from unexpected breakdowns. Emphasizes the role of the machine operator who becomes involved with routine checks and fine-tuning.

Recommended Prerequisites: 1-6

Standardization is a proven method for preventing and reducing many types of workplace waste - including duplication of effort and process contradictions. This workshop provides users with the information needed regarding standard work practices to start applying principles and methods. Participants will walk away with the ability to effectively implement select processes such as inventory, and mapping or prioritizing a work processes (definition, improvement, re-engineering).

Recommended Prerequisites: 1-6

The goal of Six Sigma is to reduce defects, manufacturing costs, and improve customer satisfaction. Six Sigma discipline begins by clarifying what measures are key in gauging business performance; it applies data and analysis to build an understanding of key variables and optimize results. We have Master Black Belts on staff to assist you in the following: 1) Executive overview training, 2) Certification training, or 3) Performing projects within your organization. Participants will have a solid understanding of the Define, Measure, Analyze, Improve, Control (DMAIC) process, the six sigma reporting structure, and the tools used within the six sigma process.

Recommended Prerequisites: 1-6

Participants will be trained in the many ways to prevent errors at the source using the “error-proofing” or “Poka-Yoke” methods. You will gain insight about this important approach and shown where to look for error-proofing opportunities to achieve zero defects. We will also show you how to implement automatic and manual principles of error-proofing, as well as techniques such as “layering”. The process includes the development of procedures and the identification & implementation of Poka-Yoke methods in the selected area.

Recommended Prerequisites: 1-6

7H Lean Performance Measures
(Formats 2,4*)

Participants will be trained in the many ways to prevent errors at the source using the “error-proofing” or “Poka-Yoke” methods. You will gain insight about this important approach and shown where to look for error-proofing opportunities to achieve zero defects. We will also show you how to implement automatic and manual principles of error-proofing, as well as techniques such as “layering”. The process includes the development of procedures and the identification & implementation of Poka-Yoke methods in the selected area.

Recommended Prerequisites: 1-6 

TAKING LEAN THINKING TO THE NEXT LEVEL – INTEGRATION

Effective project management is critical in any business environment. In this course, participants will learn how to identify the entire project life-cycle from visualization to closing. Participants will learn how to: 1) draw up a doable game plan, with a “Plan B” at every critical step; 2) Obtain the support, financing, and resources needed to do your job; 3) Plot critical paths, anticipate roadblocks, and find alternative routes. We will demonstrate the effective way to close down your project, identify profits from its lessons, and celebrate with your team.

Recommended Prerequisites: 1-7

Lean Accounting supports the transformation to a Lean Enterprise. This workshop is intended to lead participants to understand why traditional accounting is a problem, the significance of the problem, and what they can do to change their systems to promote the goals of lean. Every person in a company that has undertaken lean manufacturing initiatives needs to understand Lean Accounting Performance Measures. Decision makers need to understand what information Lean Measures give them and how to use it. Accountants need to know what information to gather and how to integrate it into their financial and overall reporting. Production managers need to know what to measure and report. Floor personnel need to know what parameters are being used to measure their performance.

Recommended Prerequisites: 1-7

In order to help businesses transform their supply chain we offer a comprehensive workshop. This course will provide strategies, tools, and techniques for executives and managers in production, purchasing, inventory control, customer service, and distribution- required to improve the supply chain.

Recommended Prerequisites: 1-7

Participants will learn the right way to schedule in a lean environment. This course will demonstrate that your computerized scheduling system and lean implementation can coexist; and, when to use one system over the other. Participants will be able to define the scope of scheduling systems, the data required, and where the shop floor Kanban system takes over.

Recommended Prerequisites: 1-7

Believing that “Lean Leaders” must ‘walk the talk’ in their habits, procedures, and offices, this course trains customers to implement lean principles in the office environment. Lean Office can be defined as a learning environment where waste elimination results in satisfied employees who successfully meet organizational goals. A lean office results from the consistent application of waste identification and elimination, problem solving, value stream mapping, 5S, visual controls, and standardized work to achieve continuous improvement.

Recommended Prerequisites: 1-7

This course will define the methodology you need to follow in order to become a JIT organization. Participants will be taught how the use JIT principles to improve processes and enable their facility to operate successfully with lower inventory levels and higher inventory turns. We will outline the process as it relates to delivery of materials by vendors, sub-contractors, or other processes under the same roof.

Recommended Prerequisites: 1-7