5S: Systematic Organization of the Workplace
A hands-on course providing instruction in how to use the 5S methods to simplify and organize your workplace to help avoid the seven wastes. It includes classroom instruction where each of the five “S” components (sort, straighten, shine, standardize, sustain) are explained in detail. Upon completion of the classroom instruction, participants will move to the work area and apply each of the five ‘S” components in a hands-on manner. The class provides an excellent foundation for any company in any industry. It is a great class to help a company from the beginning of its 5S journey or as a refresher for those who are struggling during the implementation phases. It provides many examples of “best practices” and a very structured Sustain section that attendees can take away and immediately apply in their own settings.
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One-Day Course
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The Human Side of Lean
A comprehensive journey into how Lean manufacturing principles lead to better results when the people, in any role, have a true appreciation for teamwork and the value of people. Experiential exercises support all learning points.
Attendees should have a basic understanding and experience of Lean principles as a prerequisite.
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Two-Day Course
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Integrating Green Manufacturing and Lean
Managing resource productivity is key to the greening of manufacturing. Lean can help with proper attention to a process focus and a systems approach to managing the process improvement effort. Several tools are available that can expand the Lean horizon to accommodate green manufacturing. During this program, participants will see how these resources can work together to add value to their operation’s top and bottom lines.
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One-Day Course
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Introduction to Lean: Overview of the Lean Toolbox
This course is designed to teach the basic tools used in a lean culture when problem solving. The course is designed around a factory simulation where the participants will learn how to apply lean tools in a hands-on manner. Each participant will be responsible for tracking performance through visual factory methods. As the day progresses, lean tools are taught and applied to the process. This class is the first stage in an organization’s lean transformation. It is designed to bring all levels of the organization together in a fun and fast-pace exercise, where rank and file is left outside the room. This class should be used to help create a hunger and a passion for continuous improvement. Participants will leave excited to go to the next stage of the transformation.
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One-Day Course
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Kaizen Workshop
This multi-day course is designed to have the participant learn how to problem-solve in a team environment through the use of Lean thinking. Using the principles of Lean, participants will work together to plan and implement improvements to a defined topic. Scope and boundaries will be established; the team will attack the issues until resolution is implemented. Most companies do not have enough time to effectively problem-solve, so “band aid” improvements are made. In Lean, kaizen is a way to use cross-functional resources in short periods—or bursts of dedicated time—to effectively improve processes. Kaizen is an intense, well-defined event used to help organizations problem-solve with a systematic approach. The approach utilizes people in a dynamic and fast-pace environment and usually at the origin of the issue being improved. Kaizen techniques utilize many different Lean tools such as line balancing, time observations, SMED, Value Stream Mapping, 5S techniques, and DMAIC.
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Five-Day Course
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Kanban: Inventory and Demand Management
This course is designed to introduce participants to another visual factory tool that helps control the levels of inventory along with establishing controls used for scheduling work center production. The course will discuss the reasons, rewards, roadblocks and challenges of using kanban signals and supermarket inventory to manage the movement and storage of material. Each participant will see the importance of synchronizing the information and material flow in the facility. Key characteristics such as lead time, takt time, inventory valuation, excessive changeover, material shortages, first time quality, and unbalanced processes will be discussed and the impact shown. The participant will be able to see the impact of continuous improvement on the material management system. This introductory class will give participants enough information to start implementing in their own facility.
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One-Day Course
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Lean Product Development
This intensive, hands-on workshop explores all aspects of lean product development, including elimination of cost and time barriers, building a lean product specification, the continuous-flow development process, methods of design for lean manufacturing, practical techniques for product / process co-design, and several advanced strategies for reducing unit cost and time-to-market. Each topic is reinforced by interactive exercises that demonstrate how design teams can develop innovative new products in less time and at significantly lower cost.
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Two-Day Course
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Planning Manufacturing Cells
This course provides an introduction to the planning of manufacturing cells, including the physical, procedural, and personnel aspects of cellular manufacturing. It will provide participants with a systematic, step-by-step approach useful on any cell planning project, from simple manual assembly to automated machining and fabrication.
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Two-Day Course
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Six Sigma Green Belt
This course teaches specific Lean Six Sigma tools, methods and techniques for performing business improvement and root cause analysis projects. Six Sigma performance benchmarking allows organizations to continuously strive towards perfection. Emotional decisions are replaced with logical fact-based decision-making tools. The Six Sigma Green Belt Team Leader is an important part of fostering a Six Sigma business culture by providing direction and vision to the team members as well as people in their organization. This ensures the team’s contributions make for a successful project. The course links Lean Six Sigma principles with team activities and people development to enhance measurable results in operational excellence and ensures a thriving business environment.
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Five-Day Course
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Six Sigma Yellow Belt
Six Sigma Yellow Belt is an introduction to the Lean Six Sigma principles and methodologies, and how to apply them to your specific work environment as part of a team. In a team, the tools and techniques taught are vital to the success of a Six Sigma project, resulting in business improvement and people development.
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Two-Day Course
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SMED: Setup / Changeover Reduction
This course is designed to help problem-solving teams learn how to identify the features of the non value-added setting up time or changeover equipment used in the manufacturing process. In today’s global market, manufacturers must be more flexible and have the ability to produce smaller quantities and deliver more quickly. They must be able to utilize equipment for as many different parts as possible. This new way of doing business is driving companies to invest in capital equipment and inflate their inventories. This course will help participants combat the impact these new demands are creating. The setups and changeovers comprise a series of steps that are performed to prepare the manufacturing process for a new part. The participant will learn how to define all of the features of a changeover and learn how to eliminate the waste. The elimination of wasteful activities will free up capacity, lower the need for inventory, reduce lead time, and help the organization become more flexible.
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One-Day Course
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Understanding the Tools and Best Practices of Lean Manufacturing
Lean concepts have been adopted by many successful manufacturing companies as a way to reduce costs, satisfy customers, and increase profitability. The process of "becoming lean" may mean a company-wide transformation from current operating style. This course offers a methodology for linking the goals and metrics of a project or initiative to a company's strategic goals and metrics and provides the basis for tracking the effectiveness of lean initiatives.
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Two-Day Course
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Value Stream Mapping: Diagram the Information and Material Flows in Your Business
A hands-on course that teaches students how to document and quantify material and information flow within their organizations. In today’ global market, time is very important. The Value Stream Mapping techniques help everyone in the organization understand lead time. Lead time encompasses the total amount of time needed to convert raw material into a final product. Most organizations cannot separate the “total time” into manageable pieces. This class will guide the participant through the process used to capture and document the current material and information flows for a given process. Value Stream Mapping techniques allow a team of problem solvers to come together and SEE the door to door process exactly the same. Each participant will visit the Gemba (shop floor) and walk the door to door process. A standard set of icons will be taught and used during this session. A comprehensive case study is used to allow students to practice drawing value stream maps using the standard set of symbols and icons. Upon completion of the value stream maps, the participant will learn to look for strategic areas that could be improved. Each improvement idea will be analyzed for the impact to the lead time. After improvement ideas are identified, each participant will generate a future state map.
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Two-Day Course
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