LEADERSHIP AND MANAGEMENT
Implementing lean practices is a managed process that requires clear leadership, a defined plan, coordination of resources, and robust support systems to assure transformation. Lean leadership and management offerings are intended to equip those leading the lean enterprise with the necessary skills to achieve long term success in pursuing lean as a strategic initiative.
PRINCIPLES OF LEAN FOR MANUFACTURING
The Truth Behind Results
How is it possible that small and midsized companies are cutting away so much waste and reporting phenomenal results? Many have said implementing Lean Manufacturing processes are the most positive, productive changes their businesses will see in their lifetime. As a result their companies are operating with less waste and using fewer resources to turn out quality products.
Lean 101 is an accelerated learning workshop that demonstrates the benefits of using Lean in an Order-to-Shipment environment to achieve breakthrough business performance.
Key deliverables include:
- Understanding the business case for continuous improvement to compete profitably in the global marketplace.
- Understanding of how Lean methods simultaneously reduce lead time and operational costs while improving service and quality.
VALUE-STREAM MANAGEMENT & MAPPING
Value Stream Management is an 8-step method of planning and managing the transformation process. It introduces the use of successful lean tools for selecting product families, mapping the value streams of selected families, and creating a plan and management system to transform the value stream to achieve customer expectations. The final outcome of Value Stream Management is the creation of a complete, visual plan for lean transformations. Available in training workshop or on-site implementation.
LEAN SIX SIGMA GREEN BELT & BLACK BELT TRAINING
Time and quality are the two most important measures in improving any company’s production and profit performance. Lean Six Sigma explains how to impact your company’s performance in each, by combining the strength of today’s two most important initiatives — Lean Production and Six Sigma — into one integrated program.
The first course to provide a step-by-step roadmap for profiting from the best elements of Lean and Six Sigma, this breakthrough training will show how to:
- Achieve major cost and lead time reductions in less than a year
- Compress order-to-delivery cycle times
- Reduce process variation and waste throughout your organization
Unlike its predecessors, Lean Six Sigma keeps improvement tied to business strategy. You’ll learn how to determine which projects will have the biggest and quickest impact on you strategic and financial priorities. You’ll learn the secret to eliminating the time traps that add delays and hinder speed in both service and manufacturing processes. Lean Six Sigma can show you how to permanently eliminate sources of unnecessary cost while reaching Six Sigma levels of quality, and dramatically improving shareholder value. Green Belt training is a two-week course in which attendees learn basic problem-solving tools. Black Belt training is a more rigorous four-week course covering both basic and advanced tools. The courses use materials developed and offered in partnership with George Group. Available as training workshops.
LEAN PRACTITIONER’S 9 3 CERTIFICATE SERIES
This program is tailored for manufacturing professionals leading lean initiatives who want to equip themselves with the skills necessary to be effective change agents and lean implementers. The 9 3 program consists of 9 days of simulation-based, hands-on workshops that present lean concepts, principles, tools and techniques plus a three-day rapid improvement event (Kaizen) to experience implementing newly learned lean practices in a real factory. The program is highly interactive and experiential, not simply classroom lectures and theory. It’s practical, effective and proven. Available as training workshop/implementation project capstone.
TEAM FACILITATION SKILLS TRAINING
Lean projects are most effective when deployed using teams. Beyond the technical skills of lean tools and techniques, lean experts must also possess the skill of team facilitation. A trained team facilitator is able to assume a key role in improvement teams or natural work groups. A facilitator who can advise teams, assist managers and serve as an internal process consultant is vital to the success of the lean enterprise. Participants will learn the roles of facilitator, leader and team member, skills in team building, communications, interventions, and guiding team activities. Available as training workshop.
RAPID IMPROVEMENT EVENT (KAIZEN) METHODOLOGY
A Rapid Improvement (KAIZEN) Event is a team activity aimed at rapid implementation of Lean methods to eliminate production waste in particular areas of the plant. This workshop covers the three phases of conducting an improvement event including:
- Planning and Preparation
- Implementation…The Event Itself; and 3) Presentation, Celebration, and Follow-Up.
Available as training workshop.
Equipment and Facilities are usually the most significant assets appearing on the balance sheet. The fundamental aim of lean is to increase throughput dollars using the existing capital assets. When equipment and facilities are not used effectively, it often results in insufficient capacity and causes overtime, additional equipment purchases, poor customer satisfaction and even facility expansion. Lean Asset Management offerings are geared to making the most effective use of machines and equipment, and facilities to allow the greatest throughput with the least amount of capital investment.
TOTAL PRODUCTIVE MAINTENANCE (TPM)
TPM is a method to proactively maintain machines and equipment at their peak productivity to increase return on capital assets. The 8 Pillars of TPM increases overall equipment effectiveness and helps avoid interruptions to production to achieve reduced batch sizes and increased equipment performance. It is often the first key strategy of the Lean Enterprise Operating System that is deployed since it enables the others.
Over 70% of the causes of machine failures result from just 3 things – contamination, improper lubrication, and loose nuts/bolts or other mechanical fasteners. The 7 step Autonomous Maintenance methodology forms the foundation for TPM by equipping operators to perform basic machine inspection, lubrication, and cleaning functions to dramatically decrease machine failures. This creates greater machine uptime and utilization, and begins to free up skilled maintenance technicians to focus on proactive maintenance activities by reducing ‘firefighting’ and unexpected machine failures. Available as on-site deployment project.
SET-UP REDUCTION/QUICK CHANGEOVER
This course teaches the fundamental principles of set-up reduction. The instructor will clearly define set-up and discuss reasons and barriers to reducing set-up time. Participants learn the standard methodology in applying Single Minute Exchange of Dies (SMED) to any type of set-up or industry.
PLANT & WAREHOUSE LAYOUT/RELOCATION/EXPANSION
Poor layout can result in excess handling and inventory, reduced process speed, increased expediting, and poor communication. This workshop details the steps of analyzing, designing, and implementing an improved facility layout to achieve maximum velocity of product moving through the system to produce income while minimizing the resources required. Participants learn a proven methodology to make the most efficient use of the existing facility or designing improvements for an anticipated plant expansion or relocation.