Lean: The identification and elimination of wasteful activities from all of our business processes.

Note: We customize the training materials based on business sector and process while offering flexible scheduling options that best fit the needs of our clients.

Introduction to Lean Concepts:
A basic overview of lean history, methodology, tools and benefits of doing lean will be presented in a simple but real life format. We will discuss the need for organizations to change, the concepts of value and non-value adding and several examples of waste as they exist in manufacturing, healthcare, service and non-for-profit sectors. The lean tools will be introduced and we will discuss how to best apply them to support your continuous improvement initiatives. This class is offered with and without a lean simulation.

Lean Simulation: People often learn best when they are able to see a demonstration of lean techniques in action.
In conjunction with the Introduction to Lean Concepts class, we offer a hands-on lean simulation of a manufacturing, healthcare or office process in a class room setting. The class participants will run the 1st simulation in a traditional (non lean) setting. We get class input to make process improvements before running a 2nd simulation. We then apply the lean tools to make additional improvements for the 3rd simulation. Key metrics are kept for each simulation so we can do a final comparison. Unlike some of the complicated lean simulations offered by other consulting groups in which they own the simulation materials, our simulations are simple and are yours to keep.

Value Stream Mapping:
Value Stream Mapping is an excellent visual tool designed to help you discover and quantify the wasteful activities that exist in your processes such as time delays, redundant or unnecessary steps, bottlenecks, excess inventory, travel distance, defects and problems. The class participants will create the following:

• A Current State Map (The way the process exists today)
• An Ideal State Map (Improved process based on perfection)
• A Future State Map (Improvements we can do now)
• A plan to implement recommended process changes

Management will need to choose a real life process that needs improvement and it will be the focus of this value stream mapping workshop. An ROI (return on investment) is often experienced after the team implements their ideal or future state map recommendations.

5S (A place for everything and everything in its place):
Many consider 5S, workplace organization and visual management to be the foundation of lean. The class participants will learn a powerful step by step process for industrial housekeeping and organization. The 5S's include:

• Sort (remove what is not needed)
• Set in order (organize what belongs)
• Sweep (cleaning and inspection)
• Standardize (establish common methods)
• Sustain (hold the gains)

The 5S process can be immediately applied to manufacturing, distribution, healthcare, service, office and home applications. Each step of the process will be discussed in detail with pictures of real life examples. We often do hands on implementation activities immediately following the training. We learn by doing and create a working model of excellence in your facility. Organizations often experience impressive results after implementing 5S. The benefits are measurable improvements in productivity, safety, quality, employee moral, customer satisfaction, inventory reduction and the freeing up of valuable floor space. An ROI (return on investment) is often experienced from this workshop.

Set Up Reduction - SMED (Single Minute Exchange of Dies)
Set up refers to machine, equipment or process changeover, preparation, tear down or sanitation activities.
The Set Up Reduction workshop teaches a simple set of lean tools designed to help you observe, document and measure the current state of a machine set up process. You will learn how to analyze the set up and develop new and improved methods. We often experience reductions in set up time from 25% to 50% without any capital investment. The client will need to choose one of their set up processes for the class to study. The benefits of doing set up reduction include reduced machine set up time, reduced lead time, increased machine capacity, smaller lot sizes, reduced inventory and improved customer delivery. Clients often experience a ROI (return on investment) from this workshop.

Pull Systems - Kanban: Many of us work with inadequate or complicated inventory management systems that result in too many or not enough parts being delivered at the wrong time. This also results in expediting, upset customers, frustration and additional costs.
The pull systems - kanban training workshop teaches you some different tools to manage your inventory and supplies based on simple and visual systems that can be implemented immediately. Class participants will learn where and how to set up simple pull systems to help you better manage raw materials and parts, work in process, finished goods inventory, supplies, information and paperwork in the manufacturing, distribution, healthcare and service sectors. The benefits of pull systems - kanban are improved availability of parts
and supplies, reduction in inventory and improved customer satisfaction. A ROI (return on investment) is often experienced from this workshop.

Lean Facilities Layout and Flow: Many of us are challenged with older facilities with traditional layouts resulting in excessive material handling, flow problems and additional costs. Some may have the opportunity to layout processes in new buildings.
This workshop will teach you how to better layout your old or new facility to maximize flow and minimize wasteful activities such as movement and motion. The following techniques will be discussed:

• Process Flow Charts
• Traditional and Lean Layouts
• Focus Factory Concepts
• How to Connect Disconnected Processes
• Cellular Layout Design
• Single Piece Flow
• Operations Balancing
• Standardized Work

The results achieved by applying lean facilities layout are:

• Improved Flow
• Reduced Material Handling and Costs
• Increased Productivity
• Improvements in Safety and Quality
• Reduction in floor space required
• Reduction in Lead time and turn around time

A ROI (return on investment) is often experienced from this workshop.

Total Productive Maintenance: Also called preventative and/or autonomous maintenance.
In this workshop you will learn a basic process to help you maximize your equipment uptime, extend the life of aging equipment, ensure better longevity of our newer equipment while minimizing downtime and associated maintenance costs. The client will need to choose a machine for this workshop. This is a hands on workshop in which the class will apply the total productive maintenance techniques to a machine in your facility and build a model of excellence. A ROI (return on investment) is often experienced from this workshop.

Kaizen Events:
A 3 to 5 day structured team based rapid improvement activity in which the teams have specific goals and objectives to achieve. The kaizen facilitator will lead the team through the DMAIC process:

• Define the problem
• Measure (establish metrics)
• Analyze (develop solutions)
• Improve (implement solutions)
• Control (sustain improvements)

We will utilize and apply any of the needed lean and six sigma tools required to get the job done. The Kaizen Event will conclude with a final presentation to management. A ROI (return on investment) is often experienced from this workshop.

Prerequisite: Introduction to lean or lean six sigma concepts.

Accelerated Lead Time Reduction: In today's business environment, speed is a strategic weapon.
In this hands on workshop you will learn how to increase process speed by eliminating costly delays while improving overall customer satisfaction. In one of our examples, the team reduced 1st piece manufacturing lead time from 2 weeks to 110 seconds. A ROI (return on investment) is often experienced from this workshop.

Lean Performance Metrics: Are your current business metrics helping or hindering your organization in achieving world class performance?
In this hands on workshop, class participants will list and evaluate your current state metrics and determine their impact to the organization. We will then develop a new and improved set of business metrics that will help support continuous improvement efforts and drive the organization to world class performance.

Prerequisite: Introduction to lean or lean six sigma concepts.

Other Lean Training Workshops:

• Lean Assessment: In this hands on workshop we will help you see and quantify the lean opportunities that exist within your organization.
• Error Proofing: Learn how to design simple no cost or low cost solutions that make it impossible for an error or mistake to occur in your processes.
• Level Scheduling: Learn how to better smooth and balance your work schedules while improving overall customer satisfaction.
• Operations Balancing: Learn how to create better flow and balance manual and machine operations to your customer demand.