We offer consulting services to aid in the implementation of Lean
Our Train the Trainer program allows organizations (not use company in on our website, because we will end up having all kind of organizations as our clients, not only companies) to train most of its employees using internal resources, i.e. trainers trained by us. This allows for substantial savings in comparison to fully using an outside firm.
Lean Management Temple or Pyramid
In our consuting work we use the temple below as the guiding path:
The base of the temple or pyramid comprises of
- Management Culture – working on changing human behavior in order to change the way of thinking, for example: employees who add value are most important, safety is the highest priority, and so on
- Standardized Work – implementation of standards for all repetitive tasks, training in them (TWI), control of adherence and continuous improvement
- 5S – creating a visual workplace
The pillars are;
- Problem Solving – application of PDCA and DMAIC methodologies along with analytical team problem-solving tools such as Pareto, Ishikawa, 5Why to solve complex problems
- Just-In-Time – production control via a Pull System, minimizing inventory using Kanban, Supermarket, Heijunka
- SMED – reducing equipment changeover time to less than 10 minutes
- Kaizen – continuous improvement using small ideas from all employees. Also associated with Kaizen Blitz – a 5 day workshop that eliminates waste from a selected process
- TPM – preventive maintenance practices alongside with inclusion of production operators in shared responsibility for equipment (Autonomous Maintenance)
- ZQC (Zero Quality Control) – quality built into the process based on inspection at the source, prevents errors from occurring or detects defects before they enter the next process – Poka-Yoke and Jidoka (Autonomation)
The roof is of VPM
VPM (Visual Performance Management) – visual management of KPI’s to measure the results of work in real time, solve problems and provide feedback to all
For clients interested in a holistic approach to Lean implementation we offer a continuous improvement program that combines the development of policy and strategy with forming of program structures to guide the lean implementation. A typical intervention period varies from 18 to 36 months, depending on company size and project complexity.
A typical implementation program will follow this roadmap:
- Lean Management assessment – determine the gap between current and desired performance
- Top management training – educate managers on lean tools and process improvement techniques
- Implementation planning – develop implementation policy and strategy
- Value Stream Mapping – determine an action plan for Pull System implementation
- Workforce training – train everyone on Lean concepts
- 5S – implement visual organization principles
- VPM – implement visual performance management KPI’s
- Standard work – implement standards in the workplace
- Kaizen Blitz – improve production cell layouts, reduce waste
- SMED – reduce equipment setup times
- Autonomous Maintenance (part of TPM) – involve machine operators in maintenance in 7 steps
- Planned Maintenance (part of TPM) – develop a professional maintenance department focused on prevention
- Problem Solving – attack larger repetitive problems using DMAIC and supporting tools such as 5W2H, Ishikawa, 5Why, Pareto
- Lean Office – map and improve administrative processes
For service organizations, the implementation program will follow a similar course, with the exclusion of tools applicable strictly to manufacturing, such as SMED and TPM.
Our expert consultants are ready to analyze your operation, suggest improvements and help with implementation.
For clients wishing to train a larger number of employees (typically more than 100) we offer a Train-the-Trainer Program that certifies internal Trainers in Lean methodologies.
For companies wishing to learn the application of Lean tools such as 5S, SMED, TPM or run a Kaizen Blitz event, we offer courses and workshops. Each class is customized to the client’s requirements.
A Kaizen event sometimes referred to as a Kaizen blitz, is a focused short-term project to improve a process. Tools implemented during a Kaizen event include value stream mapping, 5S, and TPM. In this workshop, you will learn how to facilitate and implement Kaizen events within your organization.
- Describe the purpose, goals, and typical flow of a Kaizen event.
- Write an effective problem statement for a Kaizen event.
- List and describe tools used during a Kaizen event, including root cause analysis, 5 Whys, and an A3.
- List and describe the roles and responsibilities of participants, including the sponsor, team leader, and team members.
- Describe techniques for working effectively as a team.
TRAIN THE TRAINER – COACHING OF INTERNAL FACILITATORS
Our Train-the-Trainer program allows an internal trainer to conduct classes and facilitate improvement workshops for company employees. A qualification process in each module such as 5S, Kaizen, TPM, SMED, etc. consists of 4 steps.
Step 1: Participate in a workshop conducted by Lean Trainers
Step 2: Co-facilitate workshops alongside a Lean Trainers instructor
Step 3: Get Certified
Step 4: Independently facilitate future internal workshops using Licensed Materials
We certify a Trainer based on his or her topic knowledge and facilitation skills. The number of sessions required to achieve certification varies from 2 to 4 and depends on the module complexity and Trainer’s experience and facilitation skills.
In order to facilitate learning, Trainers have at their disposal of a complete set of training materials, including:
- Trainer’s Manual – a detailed step-by-step guide to conducting a workshop.
- Presentation with speaker’s notes for each slide.
- Teaching Aids – worksheets, data collection forms, check sheets, assessment forms, databases, etc.
- A complete group exercise kit, if applicable.
We currently offer Train-the-Train program for the following workshops and courses:
- Lean Manufacturing Simulation
- 5S Workshop
- SMED Workshop
- Standard Work / TWI
- Value Stream Mapping course and workshop
- Administrative Process Improvement workshop
- Lean Office Simulation
- Autonomous Maintenance Workshop
- Planned Maintenance Workshop
- Kaizen Blitz Workshop
- Problem Solving Workshop
- Visual Performance Management workshop
Before starting an implementation project we typically conduct a Lean Assessment to benchmark company’s production system against best practices of Lean Management. The assessment is conducted in 12 categories that have critical influence on operational performance.
Each category is evaluated based on direct observation of work, interviews with employees and analysis of data on plant performance. Consultants also perform detailed analysis of a few critical manufacturing processes such as equipment changeover or operations in a work cell to determine numerical improvement opportunities.
The client receives a report outlining a recommended strategy for implementation of Lean Management, a summary of project costs and an estimate of potential gains.
Assessment categories are customized for each client.
Most often used are:
- Standard Work – standard practices and procedures for repetitive work
- 5S – orderliness and cleanliness in a visual workplace
- SMED – organization for quick changeovers
- ZQC (Jidoka) – mistake proofing, quality assurance
- Planned Maintenance – effective equipment maintenance
- Autonomous Maintenance – involving operators in maintenance (part of TPM)
- Just-In-Time – material control, production scheduling
- Problem Solving – approach to analytical problem solving
- Visual Performance Management – using visual measures to communicate targets and show results
- Safety – behaviors with regards to safety
- Supply Chain Management – cooperation with suppliers
- Organizational Culture – management practices, respect for people