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Training Available
5S and the Visual Factory – 1 Day
This introductory training provides participants with the understanding and the tools to begin systematically implementing a safe, visual, and orderly workplace. It focuses on the 5S’s (Seiri, Seiton, Seiso, Seiketsu, and Shitsuke) and explains in simple terms how these concepts contribute to a safe and effective North American company. The onsite implementation puts the concepts learned to work. This session should be considered for those looking to establish an ongoing approach to building a visual environment in preparation for the application of visual management systems.
5S and the Visual Factory Simulation
This 5S training offers an interactive workshop introduce the concepts of 5S and the visual workplace. This introductory training provides participants with the understanding and the tools to begin systematically implementing a safe, visual, and orderly workplace. It focuses on the 5-S’s which include Seiri (Sort), Seiton (Set-In-Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain) and explains in simple terms how these concepts contribute to a safe and effective North American company. Coupled with the 5-S training are discussions on how to make workplaces ‘visual’ including the concept of a “visual dashboard” where key performance measures are displayed simply and effectively. All content will relate to how 5-S and Visual Factory Methodologies have been used successfully.
Using ‘Lego’ building blocks, participants become team members of the Sky View Truck Manufacturing Company. The team will work together to take the company from an environment that has not implemented 5S to one that has implemented all stages of 5S as well as the concepts of visual factory. The focus will included all aspects of 5S including an introduction to auditing and understanding the impacts that 5S has on through-put, quality and cost.
5S Auditing for a Lean Enterprise – 1 Day- Managing and Maintaining 5S
This one day 5S training focuses on how to maintain and improve 5S through the effective use of 5S auditing. The interactive workshop begins with a review and discussion of the concepts of 5S as they apply to the Lean Enterprise, including both a manufacturing and office environment. This also includes a discussion on implementation and planning. The workshop then introduces the audit tools required in order to create the discipline to sustain your 5S activity through either a hands-on ‘video’ audit or directly through an audit in a host company’s facility. Coupled with the 5-S training are discussions on how to make workplaces ‘visual’ including the concept of a “visual dashboard” where key performance measures are displayed simply and effectively. All content will relate to how 5-S and Visual Workplace Methodologies have been used successfully.
Autonomous Maintenance
An overview of Autonomous Maintenance, which is segment of TPM, will be reviewed with an emphasis on what it is and an implementation plan. The workshop will review the different types of maintenance activities. The metrics that apply to maintenance, reliability, maintainability, OEE, and the six big losses will be reviewed. The group will also walk through an example of calculating OEE using an excel spreadsheet and also example from one of the participants.
Participants will walk through an implementation of Autonomous Maintenance from identifying a piece of equipment through determining the team, training plan, developing the checklists and finally monitoring the results. The “5 Whys” will be covered as a problem solving tool to determine the root cause of machine breakdowns.
Continuous Improvement Through Teamwork (C.I.T.T.) – 1 Day
This practical workshop is a concentrated version of the typical 3-day CITT training. It is intended to provide an understanding of the process and yet provide simple tools that participants can take away and apply in a Continuous Improvement environment. The workshop is presented from the perspective of what is required to become a more competitive and effective High Performance or World Class competitor. The training is focused in four: 1) Continuous Improvement Teams; 2) Effective Communication/Team Meetings; 3) Continuous Improvement Tools; 4) The CITT Process.
Effective Lean Management Skills – 4 Days
Competition is driving the need to change how we manage and lead people. One of North America’s weaknesses has been to promote people who are good technically into managerial positions based on their technical capabilities – not on their knowledge of how to achieve results through people. For many, the change was made with little training provided which created a risk of weakening the company’s technical strength, while putting in place managers who could be more effective with basic skills and tools. Today, achieving results through others has never been more critical. The roles and skill sets held by technical contributors and managers are very different. In today’s Lean environments where productivity and continuous improvement determine one’s ability to compete and win, this course provides down-to-earth, basic thinking, plus the proven tools and skills needed to achieve results through people.
Effective Office – 1 Day
If you are responsible for an office/business process or are the leader of a team responsible for an office/business process, this one-day interactive simulation/workshop is designed to provide you with a powerful-yet-simple, tool to make the business process value stream visible and to use these tools to make business processes more effective. Based on the principles of the ‘Lean Enterprise’ the workshop will include an understanding of Lean tactics, tools, and proven practices that apply to the business process professional’s role. Both current and future implementers of ‘Lean Enterprise’ thinking who want to apply the tools and practices contained in this workshop will find the hands-on format and learn-by-doing simulation approach easy to grasp and convey to others. Participants become members of the order entry team of the Sky-View Aircraft Company which has just adopted Lean Enterprise/World Class thinking to increase productivity to improve its competitive position. This approach involves participants directly and enables them see how to practically define opportunities for improvement and to integrate Business Process Value Streams with other processes both internal and external to the Enterprise.
Kaizen Event - Rapid Process Improvement … How to Use Kaizen Blitz
This one day introduction will explain the process of running a blitz, how to be successful with the tool, what not to do, and will include case studies from various manufacturers.
One of the keys to staying competitive in today's economy is the ability to implement continuous improvements throughout your company and throughout your supply network. Kaizen blitz provides a framework for sharpening competitive skills - attuning a company to the improvement possibilities in their own environment and delivering results.
Both service and manufacturing companies alike are using rapid improvement to streamline operations. They use it:
- To reduce non-value added activities.
- To streamline parts, people and information travel within a process.
- To reduce cycle time, flow time and lot size.
- To reduce set-up times.
- To reduce WIP inventories.
- to reduce floor space requirements
Most managers understand the need to reduce costs, improve cycle times and improve quality. But moving the improvement concepts onto the shop floor or into the office can be a difficult, frustrating process of running into roadblock after roadblock throughout the implementation.
Kaizen Blitz dramatically reduces the cycle time required to implement significant improvements. Target goals are met in just 3 -4 days. Management identifies target processes and improvement goals, selects the best team to work on the improvements, and empowers the workforce with education, tools and support to make changes immediately.
Lean Principles 101 – 1 Day
A stimulating and thought provoking simulation that puts the wheels under the concepts of the first day’s thinking. Lean, like swimming, cannot be taught in the classroom. This hands-on simulation is a must as it puts Lean Thinking and Lean Manufacturing into perspective. Participants assume specific roles in the Sky-View Airplane Company and use Lean Tools and thinking to escalate productivity, quality, and output. This unique approach puts Value Stream Mapping, One-Piece Flow, Plant Layout, Quick Set-up and more into perspective.
Introduction to Cellular Manufacturing – 1 Day
This hands-on workshop is focused on developing the thinking required to implement cellular manufacturing concepts. This one-day, interactive, hands-on, simplicity-driven workshop focuses on the principles of Lean Thinking, 5S, Plant Layout and Standard Work required to implement manufacturing works cells through the use a daylong learn-by-doing simulation. Participants become team members in the Sky-View Aircraft Company, a manufacturing operation that needs to adopt cellular manufacturing in order to increase productivity and through-put in its organization. The process is based on the understanding that it is people who make processes – and plants – successful and they do it by threading lean thinking, common sense, 5S, operations layout, standard work and more throughout a very busy one-day experience.
Plant Layout for Agile Continuous Flow
This team-based interactive workshop condenses the principles provided during the 2-day workshop to give participants the key techniques and methodologies needed to understand the contribution that plant layout offers in achieving Lean Manufacturing success. Participants will learn how to apply essential Lean Manufacturing techniques to reduce cycle times, increase output from the same square footage, improve quality, reduce inventories, and more. Throughout the session, extensive photographs of existing facilities will be used to illustrate the principles presented.
The Plant Layout for Flow workshop utilizes numerous tools of Lean Manufacturing methodologies including:
Introduction to Pull Systems – 1 Day
This one-day workshop includes on the floor hands-on experience and is divided into two sessions. In the first session participants obtain the ‘big picture’ interactively from a generic example based on one company’s approach to applying “Lean Thinking” and their implementation of a practical “Pull System” that reduced waste throughout their operation. The afternoon ‘shop
floor experience’ session forms participants into teams who select an area at the host facility where a Pull System could be implemented. The teams gather data, and apply the tools learned in the first session to carry out an analysis and develop a 20-day action plan that the company can follow to implement the Pull System. This session may also be delivered in a half-day format without the shop-floor component.
Lean Purchasing – 1 Day – Lean Purchasing and Supply Chain Management
This interactive session is designed for procurement-professional/practitioner teams seeking a needed, powerful-yet-simple tool to make the purchasing stream visible. Participants become members of the purchasing department of the Sky-View Aircraft Company which has just adopted Lean/World Class thinking to increase productivity and improve its competitive position. Participants learn how to practically integrate the Lean Purchasing/Procurement Value Stream with both Supply Chain and Lean Manufacturing operations. Participants focus on the company’s purchasing value streams, and learn how to use Lean thinking to identify non-value added activities, reduce waste, and improve the effectiveness of both processes and information flow with the goal of enhancing customer success.
Plant Layout for Agile Continuous Flow
This team-based interactive workshop condenses the principles provided during the 2-day workshop to give participants the key techniques and methodologies needed to understand the contribution that plant layout offers in achieving Lean Manufacturing success. Participants will learn how to apply essential Lean Manufacturing techniques to reduce cycle times, increase output from the same square footage, improve quality, reduce inventories, and more. Throughout the session, extensive photographs of existing facilities will be used to illustrate the principles presented.
The Plant Layout for Flow workshop utilizes numerous tools of Lean Manufacturing methodologies including:
Set-Up Reduction Principles – 1 Day
This hands-on workshop provides the practical concepts and understanding needed to reduce the set-up time for equipment and processes. Lean manufacturing considers most set-up time as waste and a non-value added activity that must be reduced or eliminated to increase throughput velocity and responsiveness to the customer. High emphasis is placed on understanding how set-up, and set-up issues influence behaviour and results. This is followed by the major part of the session, which focuses on the shop floor where practitioners dissect an actual real-world set-up situation. Participants trace the process through the use of a video camera to gather data, which is followed by a situational analysis, discussion of necessary team thinking, demonstration of effective brainstorming, and the approach to apply problem-solving techniques and implementation solutions. Participants typically reduce most set-up times by 50% following the process.
Standard Work – 1 Day
This hands-on workshop provides practical concepts and tools that can be used to identify waste and non-value added tasks by creating Standard Work. This workshop provides the basis for any continuous improvement project or Kaizen event that sets out to improve and standardize the work content of any process. The workshop consists of a brief initial training session to show participants the key thinking & principles that drive Lean environments. The participant will gain an understanding of the seven forms of waste from both an office and operations point of view. The majority of the session will be focused on evaluation of either a video taped process or an actual shop floor process to identify the waste and techniques to reduce non-value activities. The participants will develop new workplace designs; establish flow patterns, and Standard Work instructions
Value Stream Mapping Experience – 2 Days
This two-day, interactive workshop makes Lean Thinking and Lean Manufacturing easy to understand through both a simulation and an actual project available at the host plant. Participants are exposed to the principles of Lean by being part of the Sky-View Aircraft Company (SVAC). The process includes developing a Current State Map that will reflect the existing situation at SVAC, and then developing a Current State Map of an existing process on the shop floor or an office procedure. On Day 2 participants again revert to SVAC where they will develop a Future State Map and implement the changes to improve the company’s position. The remainder of the session is spent developing a Future State Map and Action Plan for the chosen process or procedure in the host plant.
Visual scheduling
This interactive workshop shows the importance of planning and design prior to the implementation of a visual scheduling information display on the shop floor or other operations-specific areas. A 5-step approach is used to design and build a simulated visual display board for a target area in the enterprise. Focused task teams can also address visual performance measuring & monitoring for non-production areas such as customer service, receiving, shipping, warehousing, maintenance or an aggregate view for the whole operation. The workshop shows how to install visual display systems that can be trusted and will be maintained by the process owners.
This workshop is tailored to key operations process owners, supervisors, managers, work cell and self-managed work team members who want to design & build visual scheduling and related key information sharing systems. Key information may include “status”, “issues, opportunities, corrective and preventive actions”. Also suitable for change agents and kaizen facilitators looking for more tools to empower.
World Class Fundamentals – 1 Day
World Class competitiveness demands an integrated waste-free enterprise with a clear vision that’s targeted on the customer. This one-day ‘first course’ provides everyone throughout an enterprise with the “Big Picture” of what World Class/High Performance is all about and how winning companies are competing and winning in today’s global marketplace. The roles and responsibilities involved in making it work are introduced in an open, conversational, and highly interactive way. Participants are introduced to simple terms and realities of achieving World Class performance and what they can expect when working in a Continuous Improvement environment – as well as what is required to be competitive in the 21st Century. The course will be of particular value to those preparing to embark on the path to World Class performance and want a clear idea of what to expect from the journey ahead.
Also available
The following lists additional specialized training that we continue to help make available to companies across Canada:
Learning to Count – the Financial Benefits of Lean Manufacturing
It is a common problem that Lean Manufacturing projects do not result in the hoped-for short-term financial benefit. Many excellent lean projects have been cancelled or curtailed because the benefits do not “hit the bottom line”. The reason for this is that the traditional accounting systems are designed to support mass production methods. Lean Manufacturing requires different methods for assessing the financial impact and the strategic decisions accompanying these changes. Using the Acme Stamping case study, this class shows how the financial benefits of Lean Manufacturing can be readily assessed using value stream maps, and straight-forward information from the company’s general ledger. Attendees are encouraged to bring their own current-state and future-state value stream maps so they can work on ‘live’ examples.
The outcome of the class is a team of people trained in the effective assessment of lean manufacturing. An understanding of what strategic decisions are required to make lean manufacturing highly profitable, and an initial financial assessment of one of the company’s value streams.
Lean Product & Process Design
Why pay for waste? Studies have shown that in many firms, only one hour in eight of a team member’s time is actually spent creating Value for their firm’s customers. This workshop presents a toolbox of waste-slashing methods and powerful lean design strategies that you can use tomorrow to increase the speed and efficiency of your product development process. The twelve “lean methods” described in this course enable dramatic reductions in time to market while
freeing up valuable resources for additional development work. Firms that have embraced these practical tools have reported up to 50 percent reduction in schedules, dramatic improvements in gross margin, and enhanced customer satisfaction.
Quick Response Management
The key element of competitiveness today is Speed. While speed strategies can be applied to any business, we focus on manufacturing firms. We call this strategy Quick Response Manufacturing (QRM). Firms that compete through QRM, capture market share by filling customer orders faster than anyone else, and by rapid development and introduction of new products. Successful implementation of QRM results in high quality and low cost products as well, so firms using QRM strategies become formidable competitors. This sought-after 2-day workshop is led by Professor Rajan Suri, Director of the Centre for Quick Response
Manufacturing. Dr. Suri’s work is cited as a key contributor to the evolution of Lean & Lean Thinking strategies by the Lean Research Centre at the University of Cardiff, England.
Solving the Standard Costing Problem; Lean Product Costing
Organizations seriously embracing lean thinking recognize that traditional standard costing methods give misleading and harmful information, resulting in bad decisions. Significant management decisions relating to pricing, profitability, make/buy, new product introduction, and others are seriously mishandled when standard costing is used. In this class we will show how traditional standard costing is replaced in lean organizations by simple summary direct costing of the value streams, and how to correctly approach management decision-making without the need to resort to product costing. The training class also introduces the powerful features and characteristics method for calculating product costs.
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