Courses
Course descriptions
Lean 101
Lean is about operating the most efficient and effective organization possible, with the least amount of cost and zero waste.
Waste Indentification
Waste is present in every organization, and wherever there is a business process. Learning how…
5S
Proper workplace organization and identification will decrease downtime and give the team members…
Visual Management
Shop floor visual management allows team members to control the status of their work environment.
Standard Work
Standard work is one of the most powerful lean tools and yet it is not used as often as it should…
Kanban
Kanban is a term that basically means “signboard”. It is a signalling system that is used to trigger….
Cellular Flow
Sometimes referred to as One Piece Production, Cellular Flow Manufacturing is the linking of operations or …
Problem Solving
Believe it or not, most organizations and people go about solving problems in counter-productive ways.
Setup Reduction
As the title implies, this course is about reducing the time required for setups on your equipment in order to provide…
Total Productive Maintenance
Total Productive Maintenance is simply an organizational and systematic approach to address…
Lean Leadership
Lean management is about running an intelligent business, in which everyone from the top to the bottom…
Value Stream Mapping
Wherever there is a business process that ultimately delivers a product or service to a customer, there is a Value Stream.
Kaizen
Kaizen is an intimidating word to some, but it actually is just a combination of two Japanese words…
A3 Report Training
The term A3 Report originated from the Toyota Production System as a problem solving tool.
Lean Enterprise
A continuing agreement among all the firms sharing the value stream for a product family to correctly specify value
Course descriptions
Description
Lean is about operating the most efficient and effective organization possible, with the least amount of cost and zero waste. It is an approach that requires companies to make smart use of all their resources-Technology, Equipment, and especially the knowledge and skills of their People. While manufacturing is the arena which launched a variety of Lean initiatives, and especially the Toyota Production System, the manufacturing sector is not the only industry that can benefit from the process improvement techniques of Lean. This Lean 101 class will introduce you to the fundamentals of the process and is generally taught to entire organizations as the first step on their lean journey.
What You Will Learn
- History of Lean
- What Lean IS and what it is NOT
- Overview of the entire Toyota Production System
- Current State Analysis
- Standard Work
- Visual Management
- Kanban
- Daily Kaizen
Description
Waste is present in every organization, and wherever there is a business process. Learning how to identify waste, and the cause of each type is key to reducing or eliminating the waste and improving the bottom line. Empower your team members with the tools to identify and reduce waste in their own processes as well as adjoining processes to simplify the entire value stream and focus on customer value added items.
What You Will Learn
- What Lean is and what it is NOT
- The history of Tom D Wip
- Description of the 7 types of waste
- Tools to identify the 7 wastes: Value stream mapping, Swim lane maps, 5S
- Setting action plans to eliminate waste in your systems
Description
Proper workplace organization and identification will decrease downtime and give the team members a working environment that they will be proud to work in and proud to have visitors view. 5S is a system of organizing the workplace and providing the basis for sustaining the organization.
What You Will Learn
- What is 5S?
- Phases of application
- Description of the 7 types of waste
- Workplace organization and standardization
- Basic 5S
- Five steps of 5S
- Core implementation teams
- Prepare the event
- Scan the area
- Analyze the data
- Identify best practices
- Select, test, and adopt solutions
- Reasons for inadequate implementation
- Keys to success
Description
Shop floor visual management allows team members to control the status of their work environment. Giving the production team the information necessary to control the profit and loss of their own work environment is one of the single largest steps companies can take to increase the efficiency of their business. Learn the tools and steps necessary to implement a successful Visual Management System in your facility. No matter what your business or industry is, your team will benefit from the Visual Management tools you will take home from this training.
What You Will Learn
- Introduction to Visual Management
- Visual communication
- Team territory
- Visual documentation
- Visual production control
- Visual quality control
- Process indicators
- Making the process visible
- Implementing visual communications
Description
Standard work is one of the most powerful lean tools and yet it is not used as often as it should be for maximum benefit. This tool forms the basis for “Kaizen” or continuous improvement by documenting the current best practice and consists of three elements: Takt, or cycle time; Work Sequence; and Standard WIP.
What You Will Learn
- Time observation
- Process capacity
- Standard work combination tables
- Standard work layout
- Takt time
- Work balance chart
- Standardized work operation guide
- Machine capacity chart
Description
Kanban is a term that basically means “signboard”. It is a signalling system that is used to trigger action and is used to achieve just-in-time production and help control inventory levels by linking processes that are separated by distance or a constraint. In other words, it is a systematic way of adapting production to changes caused by problems and demand variations.
What You Will Learn
- What is Kanban
- Push vs. Pull
- Kanban and MRP-Working Together
- Order Point System
- Manual Kanban
- Automated Kanban
- Internal Move Card
- Production Card
- Broadcast
- Load smoothing and sequencing
- Kanban Prerequisites
- Implementing Kanban
Description
Sometimes referred to as One Piece Production, Cellular Flow Manufacturing is the linking of operations or machines into groups based on a group or family of parts. This makes production more responsive and allows a better response to problems such as defects, scheduling, and maintenance. Learn how One-Piece Flow and Kaizen Techniques work together.
What You Will Learn
- Basic concept of One-piece production
- Henry Ford-founder of the concept
- Market-oriented production
- Rules and conditions
- How to achieve
- Process-razing techniques
- Elimination of conveyors
- U-shaped cells
- Simulation of technique
- Implementation
Description
Believe it or not, most organizations and people go about solving problems in counter-productive ways. Without identifying the real, or “root” cause of the problem, any fixes you put in place are just band-aids and mask the issue rather than fix it for the long term. There is a process for finding the root cause, analyzing the problems, and implementing processes to ensure the problem does not recur.
What You Will Learn
- Introduction to problem solving
- Brainstorming
- The 5 M’s
- Ishikawa (fishbone) diagram
- Pareto chart
- The 5 Why’s
- Quality circles
- Quality function deployment
- Best-line certification
Description
As the title implies, this course is about reducing the time required for setups on your equipment in order to provide more productive time and eliminate waste in the changeover process. Called Single Minute Exchange of Die, or SMED for short, this is a process of rapid changeover allowing you to switch from one product run to another in as little time as possible.
What You Will Learn
- The structure of production
- Setup operations in the past
- Fundamentals of SMED
- Techniques for applying SMED
- Applying SMED to internal operations
- Basic examples of SMED
- Effects of SMED-The relationship between processes and operations
Description
Total Productive Maintenance is simply an organizational and systematic approach to address equipment effectiveness issues. TPM is critical to the complete Lean process because if the process capabilities are being sustained, but equipment uptimes and run rates are not predictable and maximized, the entire process becomes clogged with extra WIP to compensate.
What You Will Learn
- What is TPM?
- Is it right for you?
- Preparing for TPM
- Establish organizational policy
- Form master plan
- Implementation of TPM
- Importance of small groups
- Seven levels of autonomous maintenance
- Measuring Overall Equipment Effectiveness (OEE)
- OEE calculation
- Quality rate
- Showing the results of OEE
- The power of OEE
Description
Lean management is about running an intelligent business, in which everyone from the top to the bottom of the organization is aware of the business’s capabilities and ensures that they are used appropriately and continuously improved. This course will teach your first and second line managers and supervisors what is required to promote and foster an environment that is built on the idea that you are never good enough, and that you must always be in a mode of continuous improvement in small steps every day.
What You Will Learn
- Defining leadership
- Defining LEAN leadership
- SQDCM
- The supervisor’s role
- The morning market concept
- Roles: Team Leader, Group Leader, Assistant Manager, Section Manager
- Daily schedule of shop floor activities
Description
Wherever there is a business process that ultimately delivers a product or service to a customer, there is a Value Stream. A map of this value stream is simply a visual tool used to follow the stream of material, information, machines, and manpower through the system beginning with the customer and working back to the beginning of the process. Along the way, the tool helps shine a bright light on areas of waste in any of the resources and helps identify areas for further improvement through Kaizen events.
What You Will Learn
- Introduction to Value Stream Mapping
- Material and information flow
- The value stream manager
- Using the mapping tool
- Current state map
- Characteristics of a Lean Value Stream
- Future state map
- The value stream plan
- Breaking implementation into steps
- Value stream improvement is the job of management
Description
Kaizen is an intimidating word to some, but it actually is just a combination of two Japanese words meaning “Good Change”. Kaizen is really the practice of continuous improvement of any business process, be it the shop floor, functional departments like Engineering, Administrative, Sales, or service industries like Healthcare, and retail. A Kaizen Blitz is simply creating and sustaining continuous improvement teams to capture the current conditions, address business barriers, and implement strategies and solutions that bring bottom line results.
What You Will Learn
- Types of Kaizen workshops
- Preparing for a workshop
- Training and preparing the team
- Conducting team leader meetings
- Assessing the current state
- Determining improvement initiatives
- Implementing improvements
- Making final adjustments
- Determining a monitoring plan
- Follow-up and sustainability
Description
The term A3 Report originated from the Toyota Production System as a problem solving tool. The idea is that if you contain the problem on one sheet of paper, you will be better able to focus your thinking. The designation A3 simply refers to the international designation for a size of paper that is roughly equivalent to the U.S. 11″ x 17″ paper size. Using this tool properly provides a very structured and focused approach to solving a problem. The A3 report is a way of describing a problem and a solution plan in the form of a story that has a beginning and an end. You can hand write your A3 (in fact, it is recommended for flexibility), and you don’t need any computer software or special tools.
What You Will Learn
- Elements of an A3 report
- Proper sequencing of the elements
- Questions to ask before starting
- Who owns the process
- Who should be on the team
- The goals of the process
- How the story gets told
- Getting started
Description
A continuing agreement among all the firms sharing the value stream for a product family to correctly specify value from the standpoint of the end customer, remove wasteful actions from the value stream, and make those actions which do create value occur in continuous flow as pulled by the customer. As soon as this task is completed, the cooperating firms must analyze the results and start the process again through the life of the product family. (Womack and Jones 1996, p. 276.) See definition: From the Lean Lexicon 5th Edition
Lean Concepts Inc will consult and train your team on the implementation to set your organization on a Lean Journey to achieve a success Lean Enterprise.
What You Will Learn
- The Lean Enterprise level is achievable when the organization utilizes lean principles throughout the organization (Operations, HR, Customer Service, Engineering, Product Design, Sales).
Proven techniques for every industry
