Rapid Operational Improvement   
Training Business to become lean
  
 
Teach them to fish
"I learned more in just the first 3 sessions than I have learned about Lean in any other course I had taken."

Leslie Hagle,
West Coast Paper.

Lean & Flow Seminars Descriptions:

Executive Overview (4 hours)
Executive Summary (8 hours)
Employees' Lean Overview (4 hours)
Leadership and Staff Introduction Class (16 hours)
In-house training course (40-hour)
Kaizen Leader Certification Training (90 days)

Executive Overview (4 hours)

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This four-hour seminar will provide Executives a high-level introduction to Lean (Toyota Manufacturing System) and will explain what happens in the business, discusses the commitment required by management and a brief demonstration of the power of Lean. The class explains the connection between the Lean efforts, business plans, and meeting goals and objectives. Management and high-level leaders will gain an understanding of the Lean philosophy and how to begin to apply Lean in their business.
This seminar can be directed to manufacturing, front office work, healthcare and customer service industry or generalized for a mixed group of executives

Executive Summary (8 hours)

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This eight hour seminar will provide these Leaders an introduction to the principles of Lean and will demonstrate some of the basic tools used to identify wasted efforts in the workplace. Leaders can later use this knowledge to review their business processes. This review will support their personal understanding of how Lean will assist their workplace improvements to reduce costs, improve quality and save time. The class explains the connection between the Lean efforts, business plans, and meeting goals and objectives. Management and high-level leaders will gain an understanding of the Lean philosophy and applying it in their business.

Employees' Lean Overview (4 hours)

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This class provides the supervisors and other employees an introduction to the philosophy of Lean and will demonstrate how it can support improvements in their own workplace. By the end of the class they will have a basic understanding of the seven forms of waste; they will have hands-on experience with a basic waste analysis tool, available for immediate use in the workplace. Tools demonstrated will be applicable for waste analysis in any industry or work group. The power of this class is that it facilitates employee support for Team-based changes in support of the business objectives.

Leadership and Staff Introduction Class (16 hours)

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This class provides the supervisors and other employees an introduction to the philosophy of Lean and will demonstrate how it can support improvements in their own workplace. By the end of the class they will have an understanding of the seven forms of waste, hands-on application of the basic waste analysis tool, an understanding of the principles and value of 5S and Visual Controls, the four components of applying Standard Work and the basics of creating a Value Stream Map. This will give employees the foundation of Lean and will build a base of Lean understanding and knowledge needed to pave the way for employee support of Lean in any organization. Each of these tools can be used back on the job so they can begin to support change and the business objectives. This off-site class is broken into smaller sessions which can allow the employee time to use the tools back on the job and discuss their personal results.

In-house training course (40-hour)

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This teach-and-apply structure demonstrates to employees the foundation of Lean, develops a basic knowledge of Lean's power, and begins to develop the needed Lean skills needed to pave the way for employee support of Lean in any organization. This hands-on course provides Leaders, supervisors and other employees the deeper look at the philosophy and tools of Lean. This seminar provides your team the opportunity to apply the key tools inside your own business. During this course, students will identify previously unknown wastes, and by the end of the class they will have developed a usable plan to improve quality, reduce lead time and costs in the workplace. In group activities they will:

  • Understand how to identify the seven forms of waste and have hands-on application of the basic waste analysis tool
  • Recognize the value of 5S (workplace orderliness) and Visual Controls improves their own workplace and document where to use these tools
  • Be familiar with the four components of applying Standard Work in the workplace and how to create Standard Work
  • Construct a high-level Value Stream Map and a future State Map
  • Recognize the need to make improvements in their own workplace
  • Have an understanding of the necessary structure and planning necessary for effective improvement activities (Kaizen/Rapid Improvement activities)

This on-site and hands-on course is a full 40-hour program which guarantees that employees use the tools on the job to build skills, knowledge and abilities.
At your closing report-out presentation, YOUR team will provide a comprehensive report on the condition of the studied process and make specific recommendations for your business.

This course can be provided in a single business entity can be a shared-training with other businesses located nearby, or can be hosted by a primary business to share the costs and build on the learning opportunities.

Kaizen Leader Certification Training (90 days)

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As your company executes effective improvement efforts, trained Kaizen Leaders become more important. This training builds on the 40-hour course and supports the skill-building of one or more Kaizen Leaders in your company. (Kaizen is a process improvement effort). Your identified team leaders will gain skills to plan, facilitate and follow-up on your improve efforts. This is an in-house training designed to create your own Team leaders.

This is a support effort and allows your leader(s) to work independently and then demonstrate their efforts to a Lean Expert in a weekly meeting, or on-call. This teach-and-coach model will create your in-house leader without the expense of hiring a fulltime lean expert. Your leader(s) will apply the Lean tools to focus on a line of business, develop a plan for improvement, support the necessary data gathering of that line, and prepare and conduct improvement events. Initially this support will include direct facilitating support and as they gain skills, this direct support effort reduces. The intent of this training is support the skills of your folks, building Lean capacity, and reduces the need for external Lean help for routine improvement efforts.
 

In-House Lean Training Series

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This series of 7 courses will educate your employees about the link between the Company's Vision for the future and Lean Manufacturing Strategy to achieve these core principles and give them the tools to support your Vision.  This course will provide your organization a series of classes, beginning with an introduction to Lean Manufacturing and concepts for a foundation about waste, and progress through the many parts of Lean�s strategy to learn the philosophy and gain the skills needed to improve their work area and support others.
When finished with the first course a student will begin to think about what is value and what is waste in the activities performed each day.  Most importantly, this course is the first step in becoming a contributor to changing processes, for the better, in their own work areas.  As the sessions progress through the Lean Manufacturing philosophy and guiding principles, each person will gain hands-on training in the use of Kaizen Workshop Tools.

Each course will have exercises to drive home the need for those skills and will provide them the basic knowledge needed to perform those skills.  In each course, assignments will be given and either an exam or project will test them for skills knowledge or usage.


 
RECOGNITION OF ACHIEVEMENT

Upon completion of each level the student will receive individual and personal recognition of achievement, a company-recognized level of skill attained, and a certificate that can be framed. Achievement is recognized by a series of 7 levels.  The Company-recognized levels will be associated with the level of skills, knowledge and understanding of the tools and philosophies as follows:

Level 1- Basic Lean

Level 2- 5S and Visual Controls

Level 3- Standard Work

Level 4- Kaizen Event Management

Level 5 - Operational Availability Tools

Level 6- Value Stream Management and production leveling

Level 7- 3P Techniques and ability to train others Lean techniques and Philosophy

The Level Seven Achievement represents significant achievement in both technical skill and competence in the use and understanding of the Lean philosophy and tools.  Each level will be achieved by successfully completing the related course work, and by continued use and competence in creating your Company Production System.

Level Seven Certification

To become Level Seven certified the individual must demonstrate knowledge of lean concepts and the ability to:

  • Evaluate potential workshop opportunities.
  • Set workshop objectives.
  • Lead preparation for a workshop by selecting and using the right tools.
  • Coordinate activities of workshop participants.
  • Facilitate teams during workshop events.
  • Teach Lean principles to workshop participants.
  • Properly use the tools of the Kaizen Methodology
  • Get outside help or resources when needed.
 
  
 

 

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