Module 1

Lean Enterprise Overview
lean manufacturing - 5S - visual controls - kaizen - value streams - pull - mistake proofing - quick changeover - six sigma

Module 2

5S and Visual Controls
elements of 5S - workplace organization - implementing 5S - visual factory

Module 3

Kaizen
what is kaizen - history - implementation steps - kaizen blitz - roadblocks

Module 4

Value Streams
identifying value streams - value stream mapping - current & future states - unique situations - enhancing the future state - implementation - roadblocks

Module 5

Pull, JIT, Kanban, Demand Flow
pull - the problem with inventory - just in time - kanban - one piece flow - demand flow - standard work - takt time - production smoothing

Module 6

Poka Yoke and Mistake Proofing
what is mistake proofing - everyday examples - effectiveness and ROI - error proofing and SPC - inspection techniques - types of poka yokes

Module 7

Quick Changeover and SMED
changeover and changeover time - traditional setup characteristics  - single minute exchange of dies - SMED process steps - implementation

Module 8

Cellular Manufacturing and Plant Layouts
fundamentals of plant layout - process layouts - product layouts - fixed layouts - hybrid layouts - cellular manufacturing - implementing cells - part families

Module 9

Activity Based Costing and Lean Accounting
what is activity based costing - cost accounting systems - traditional cost
systems - activity based costing - implementing ABC - benefits and limitations

 

 

What is Covered in Lean Enterprise Overview?

This workshop will provide participants with a clear understanding of the fundamental principles behind Lean and the key tools in the lean toolbox.

• The evolution & definition of Lean
• Lean manufacturing concepts
• Defining Product Value in terms of the Customer
• What are the Lean Principles?
• Why should you reduce batch sizes
• An introduction to the most used Lean tools (5S, Kanban, Poke Yoke, and Quick Change
• How measurement impact lean behaviors

Participants also explore the Lean implications for Management, Leadership, and Culture Change. They discover the impact of Lean on each of them as individuals and for the organization as a whole.

This two-day seminar is a must for those wanting to gain an understanding of what Lean is all about. During the seminar the participants will be involved in a role play simulation where they will learn to identify the 9 types of waste and what causes them.

In addition, there will be a numerous exercises keyed to their company’s processes, which are used to show the participants in tangible terms the benefits expected from improvements that they will identify for implementation. These activities serve to create enthusiasm and a realization of what can be achieved when they return to their workplace.

What Can Participants Do After Taking The Workshop?

Because of the training, persons will be able to:

• Understand the concepts of Lean
• Learn what your company can gain by Going Lean (Cost, Quality, Service, and Flexibility)
• Acquire the knowledge to become a Lean enabler in their company

Understand how to:

• Apply the Lean Principles
• Understand the 7 types of waste
• Understand Value from the Perspective of the Customer
• Understand the advantage of Flow vs. Batch Processing

 Seminar Agenda

• Defining Lean
• What is Value
• The 9 types of Waste
• The Lean Toolbox
• Geo-Shape Hands On Simulation
• Leadership & Culture Change
• Measurement and behavior
• Conclusion

How is Lean Enterprise Overview Put Together?

The workshop is two eight-hour days and is highly interactive.  Participants learn the background of the Lean methodology and how it applies to them.  They learn the principles and application of the Customer-Supplier  methodology and how waste occurs by role-playing in a simulation of a typical company and practice it by working on exercises and other examples.  All participants will receive a reference manual of the workshop.

 

What is Covered in the 5S System?

How 5-S Transforms the Workplace

How to lay the proper groundwork to implement 5S at your company and make sure it is successful. Why you should be demanding about 5S. The importance of taking photographs prior to the start of the project.

1S—Sort
Different kinds of waste and how to identify opportunities for eliminating it. The Red Tag and Three-Color Tag process. Developing and using a Red Tag Inspection Form and Log. Understanding why Red-Tagged items must be removed immediately, and what to do with them after they have been removed.

2S—Set
How to implement the concept of a place for everything and everything in its place. Before and after pictures from companies that have successfully adopted 5S. How to make it obvious where things belong. The Set Inspection Form and how to use it. An analysis of the kinds of waste to eliminate. Correct storage of tools and dies, with illustrations from successful companies (tool boards, carts, shadow boards, floor markings, and more). Before and after pictures of Set. Some new ideas.

3S—Shine
The problems that Shine will solve. The four key steps for implementing Shine. Creating an effective Shine Inspection Sheet. Eliminating common shop-floor equipment problems. Visual tools that will ensure long-term success. The Initial Cleaning Plan. Before and after pictures.

4S—Standardize
The consequences of not standardizing. Four steps to guarantee success. How to make standard conditions visual. Samples of a Job Schedule Chart and Standardization Checklist by work area. Monthly Work Place Organization Scorecards. Arrow Diagrams and Area Maps. Why the key is discipline and prevention.

5S—Sustain
Why Sustain is critical. Why 3S does not do it. The five conditions required to make Sustain a habit. Dealing with Bad Apples, Energy Vampires, and Dream Killers.

What Can Participants Do After Taking the Workshop?

1. Apply the simple yet powerful principles of 5S to dramatically increase your facility's productivity, eliminate clutter, improve safety and boost employee morale.
2. Understand the difference between a 5S workplace and a traditional workplace.
3. How to design and implement an effective program for your operations.
4. How Visual Factory Management supports and complements the 5S System.
5. Where and when to use visual devices to guarantee optimum 5S results.
6. Why 5S is essential to an effective visual factory management plan.
7. Identifying the benefits of a 5S program at your company.
8. The tools and techniques that sustain 5S.
9. How to eliminate workplace clutter, dirt and disorganization at its source.
10. The safety factor: how a 5S program eliminates hazards and creates a safer, more productive workplace.
11. How to get and keep management commitment for your 5S initiative.
12. Avoiding the common mistakes when implementing a 5S System.
13. Harnessing the power of a 5S workplace.

How is 5S and Visual Controls Put Together?

The workshop is one eight-hour day and is highly interactive. Participants learn the background of the 5S and Visual Controls system and how to implement it to eliminate waste, dirt, clutter, inefficiency and other stumbling blocks to excellence. Participants will study many examples, and reinforce the learning experience by solving practice problems, both as individuals and in teams. All participants will receive a reference manual of the workshop.

What is Covered in Kaizen Principles and Tools?

Kaizen is a critical tool supporting companies and organization in their ongoing improvement activities identified through enterprise Process Stream Mapping.

Kaizen events improve end to end processes through the introduction of flow and pull to improve lead time, process flexibility and customer responsiveness. Kaizen events move companies away from traditional lengthy projects where valuable resources spend more time in meeting rooms and completing updates than in making change happen.

Kaizen is a focused approach that empowers participants to not only identify root cause and determine solutions but most importantly to implement the change. Time and effort is spent on the shop floor or wherever the value stream problem exists.

This one–day workshop will provide participants with a clear understanding of the fundamental principles behind Kaizen and the key tools in the lean toolbox. During the seminar the participants will be involved in numerous group activities to deepen their understanding of the Kaizen methodology.

In addition, the class activities and exercises will be keyed to their company’s processes, so as to show the participants in tangible terms the benefits expected from improvements that they will identify for implementation. These activities serve to create enthusiasm and a realization of what can be achieved when they return to their workplace.

What Can Participants Do After Taking the Workshop?

Upon completion of the training, participants will be able to:

• Understand the concepts of Kaizen
• History
• Tools of Kaizen
  • Flow Charts
  • Cause & Effect Diagram
  • Check Sheets
  • Histograms
  • Pareto Charts
  • Scatter Diagrams
  • Brainstorming using Nominal Group Techniques
• How to Kaizen—Plan, Do, Check, Act
• The Kaizen Blitz
• Roadblocks to Success

The Kaizen workshop consists of classroom activity and application of the tool on an actual problem as identified through your Enterprise Process Mapping Implementation Plan. The actual workshop time is dependent on the Value Stream problem / activity that the company selects.

At the completion of the Kaizen workshop, the participants will understand Kaizen as a Lean tool and will have identified changes in support of their Value Stream.

How is Kaizen Principles and Tools Put Together?

The workshop is one eight-hour day and is highly interactive. Participants learn the background of the Kaizen methodology and how it applies to them. They learn the principles and application of the Customer-Supplier methodology and how waste occurs by working on exercises and other examples. All participants will receive a reference manual of the workshop.

What is Covered in the Workshop?

Value Stream Mapping

• What is a Value Stream?
• How Value Stream Mapping gives a broad view of an operation from supplier to customer.
• When and where to use Value Stream Mapping
• Selecting the Value Stream
• VSM symbols and meanings
• Steps to Value Stream Mapping
• Elements of Lean and how VSM highlights their use and application.
• Getting to the "Future State"
• How to use Value Stream Mapping to develop your Manufacturing Strategy

Process Mapping

• When and where to use Process Mapping.
• Waste and why it is so difficult to identify.
• How to think in "Process" terms rather than "Activity" terms.
• How to define the product for a process map.
• Levels of detail- Macro, Micro & Sub-Micro
• Symbols & Conventions and how to use them.
• How to facilitate process mapping-- detailed instructions, hints and how-to's.
• How to streamline a process and build a "future state" map

What Can Participants Do After Taking the Workshop?

In this hands-on, practical workshop, participants learn about both Value Stream Mapping and Process Mapping. They then apply their new knowledge to actual processes and value streams from their own factory or office. 

Value Stream and Process Mapping both help visualize complex manufacturing or business systems, identify waste and guide improvement efforts. The two techniques give different perspectives and both have a place.

• Learn the core concepts of Lean and how Value Stream projects help pave the way on the lean journey.
• Learn the Value Stream methodology, it’s steps, tools, and application techniques
  Understand how to effectively use Value Stream to attack cost, defects, cycle time and other waste.
• Learn how to form Value Stream teams, facilitate the agenda for developing Value Stream improvement projects.
• Be able to capture the gains and cascade the importance of standardization and cultural change throughout the organization.

How is the Value Stream Workshop Put Together?

The workshop can be either a one or two the eight-hour day session and is highly interactive. Participants learn the background of the Value Stream methodology and how to develop and implement it in their company to reduce process complexity and cycle time. Participants will study many examples, and reinforce the learning experience by solving practice problems, both as individuals and in teams. All participants will receive a reference manual of the workshop.

What Is Covered In The Pull/Kanban System ?

Pull / Kanban is a method of controlling the flow of production through the factory based on a customer’s demand. Pull Systems control the flow of resources in a production process by replacing only what has been consumed.

The Pull/Kanban Systems workshop illustrates how to link manufacturing output to customer demand. Participants are lead through a process for designing and implementing a pull system, using hands-on exercises. This group training exercise is designed to precede a Pull/Kanban implementation, or Kaizen event.

Day 1

• Review One-Piece Flow Cells and Process flow in a Cell
• Locating Cells in your Value Stream
• How Supermarkets work
• Locating Supermarkets and Sizing Supermarkets in your Value Stream
• Types of Kanbans - Visual Kanbans, Withdrawal Kanbans, Production
• Kanbans, Supplier Kanbans
• How to construct a Kanban Card
• Constructing Kanbans for your Value Stream

Day 2

• The 7 Rules of Kanban
• Applying the Kanban Rules to your Value Stream
• Water Spiders - Milk Run Routes, Milk Run Frequencies,
• Materials Handling Systems (review)
• Load Leveling with the Heijunka Box
• Implementing Heijunka in your Value Stream

What Can Participants Do After Taking The Workshop?

Workshop participants will be able to apply the principles of  Kanban to any area of your organization. As a result, your value streams will require scheduling to occur at only one process; the rest will controlled by Pull and Flow.

Inventory levels will be reduced while simultaneously increasing on-time delivery to the customer. Lead time will be dramatically reduced, because process will only produce according to actual customer consumption (as opposed to an anticipated demand). As a result, your value stream will be able to quickly adjust to changes in customer demand.

Objectives:

• Introduce the concept of Pull
• Demonstrate the benefits of Pull using a Kanban simulation
• Learn how to calculate inventory requirements
• Show several types of Pull systems
• Connect areas of Flow within your facility
• Create a plan to further reduce the inventory within the Pull system

How Is Pull/Kanban Put Together?                             

The workshop is two eight-hour days and is highly interactive.  Participants learn the background of the Kanban system and how to implement it to eliminate waste, dirt, clutter, inefficiency and other stumbling blocks to excellence. Participants will study many examples, and reinforce the learning experience by solving practice problems, both as individuals and in teams. All participants will receive a reference manual of the workshop.

 

 

Workshop Description

Mistake-Proofing, Poka Yoke, or error-proofing as some people call it, refers to techniques that make it impossible to make mistakes.  Mistake-Proofing techniques can drive defects out of products and processes and substantially improve quality and reliability.   Understand the philosophies, techniques and devices that great companies use to strive for zero-defects. Alignment devices, detection equipment, sensing switches, counters and checklists are just a small part of the overall approach. In the workshop you will learn more about:

• Why is it important?
• What is the Poka Yoke System ?
• Principles of mistake proofing
• Multiple methods and poke-yoke devices used to prevent errors
• Tools to encourage the discovery and correction of errors
• Techniques for involving your workforce in mistake-proofing

What Can Participants Do After Taking The Workshop?

At the completion of this training program, the participants will be able to understand the impact of cost of quality on company profits. Participants will understand the basics of error proofing and how to implement an effective mistake-proofing program. Elements covered include:

• Building quality into the process
• Cost of Quality
• Causes and Types of Defects
• The Mistake Proofing Process
• The Zero Defect Strategy - Selected Inspection, Correcting Function, Check Methods
• Error Proofing Devices
• Warnings versus Controls
• Applications

How Is The Workshop Put Together?                              

The workshop can be customized in either one or two eight-hour days and is highly interactive.  Participants learn the background of the Poke Yoke methodology and how it applies to them. 
They learn the principles and application of the Poke Yoke  methodology by role-playing in a simulation of a typical company and practice it by working on exercises and other examples.  All participants will receive a workbook manual of the workshop. 

What Is Covered In Quick Change/SMED?

Single Minute Exchange of Die, or SMED, is one of the cornerstones of Lean Manufacturing. Originally conceived by Japanese industrial engineer, Dr. Shigeo Shingo, focuses on the reduction of machine and die set-up time , thereby improving productivity, enabling more flexible production and reducing inventory and overall cost. 

The approach was quite simple:  separate set-up time into "internal" (done in production, flow interrupted) and "external" (done outside of production, flow not interrupted) activities, convert as many internal activities to external activities, and then make both activities as efficient (reduce effort, cost, time, complexity, etc) as possible.

Objectives:  This one-day, interactive workshop will provide participants, via a presentation and an interactive simulation, with an introduction to Lean Manufacturing concepts and applications, with primary focus on Single Minute Exchange of Dies (SMED).  The goal of this workshop will be to enable your team to successfully complete a quick die change project. This proven approach has several key benefits:

• Students are able to apply what they have learned in class in a practical, real-world environment

• Proof of concept leading to rapid acceptance and adoption (change management and communication)

• Financial benefits derived from project (rapid return on training investment)

• Repeatable SMED process that your organization can leverage for future projects

What Can Participants Do After Taking The Workshop?

In this workshop participants will learn inexpensive techniques to achieve quick changeovers.

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 teams involved in lean conversion with the practical tools and methods needed to radically reduce changeover time in the office or on the shop floor. Typical results from this class are 70% to 80% reduction in set-up time with little or no capital investment.

Key Learnings:

• Introduction to Lean Manufacturing
• Kaizen, 5S and their relationship to SMED
• Introduction to Quick Die Change (SMED)
• The Benefits of Quick Die Change to Your Organization
• The Four Basic Phases of Set-Up Reduction
• The Eight Principles of SMED
• Assessing the Process: Internal versus External
• Set-Up Process Optimization & Continuous Improvement

How Is Quick Change/SMED Put Together?

The workshop is one eight-hour day and is highly interactive.  Participants learn the background of the SMED system and how to implement it to eliminate time, inefficiency and other stumbling blocks to excellence. Participants will study many examples, and reinforce the learning experience by solving practice problems, both as individuals and in teams. All participants will receive a reference manual of the workshop. 

What is Covered in Lean Office Training?

This workshop is designed for personnel in sales, finance, purchasing, service, and all areas of the organization that may be considered as support functions. 

The course includes practical examples of how to apply Lean tools such as 5S, 7 Wastes, and Value Stream Mapping to an office environment.  You will learn how to objectively evaluate your office so you can identify waste and identify your real customers and understand their requirements.

Participants also explore the Lean implications for Management, Leadership, and Culture Change. They discover the impact of Lean on each of them as individuals and for the organization as a whole.

This two-day seminar is a must for those wanting to gain an understanding of what Lean is all about. During the seminar the participants will be involved in a role play simulation where they will learn to identify the 7 types of waste and what causes them.

In addition, there will be a numerous exercises keyed to their company’s processes, which are used to show the participants in tangible terms the benefits expected from improvements that they will identify for implementation. These activities serve to create enthusiasm and a realization of what can be achieved when they return to their workplace.

What Can Participants Do After Taking The Workshop?

Because of the training, persons will be able to:

Understand the concepts of Lean
Learn what your company can gain by Going Lean
(Cost, Quality, Service, and Flexibility)
Acquire the knowledge to become a Lean enabler
in their company
Understand how to attack the 7 types of waste
Design and implement a 5S audit program
Create a visual office
Generate a structured program to eliminate waste
Design current and future state maps of their environment

Seminar Agenda

» Defining Lean
» What is Value
» The 7 types of Waste
» The Lean Toolbox
» Geo-Shape Hands On Simulation
» Leadership & Culture Change
» Measurement and behavior
» Conclusion

How Is Lean Principles & Tools Put Together?                             
           
The workshop is two eight-hour days and is highly interactive.  Participants learn the background of the Lean methodology and how it applies to them.  They learn the principles and application of the Customer-Supplier  methodology and how waste occurs by role-playing in a simulation of a typical company and practice it by working on exercises and other examples.  All participants will receive a reference manual of the workshop.