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Lean Fundamentals

Five S Training

Students are assigned a real life area to work on at the site on the floor or in the office at the workplace. Students learn to work together to solve problems.

Who should attend? Cross functional teams including operators and managers representing all shifts.

Purpose: Show teams how to work together to solve real-life problems, organize and sustain the workplace.

Benefits: Reduces costs associated with searching for tools and materials and instills pride in the workplace.

Course Options: FIVE S Training, FIVE S Audits, FIVE S Train the Trainer, FIVE S for Managers, How to Sustain FIVE S, Longer Term FIVE S Consulting

Course Length: Varies typically one week of training followed up with maintenance weks

Course Fee: Varies based on type of training and implementation. Course must be tailored and approved by the company prior to initiation. Course requires Leadership participation and mentoring of team(s). Course requires significant contribution from the CEO, Site Leader or Works Manager

Max Participants: 24 (four teams of six persons)

Lean Fundamentals Overview Seminar

Course Length: 1 Hour

Course Content:

Course Fee: See Price List. Training room and meals to be furnished by the Client. Course may be tailored to a company for an additional fee.

Max Participants:

Prerequisites: None

Who should attend?: Business Executives, Owners, Senior Leadership Team, Prospective Lean Team Members

Purpose:

Benefit:

Lean Fundamentals Seminar I

4 to 6 Hours

Participants will receive a broad-based overview of lean manufacturing and lean thinking fundamentals. Topics include video comparisons of batch to one piece flow environments, lean industrial and process engineering analysis, standard work, job standardization, typical results of lean implementations and videos of world class operations. Differences between Kaizens, Demand Flow and other implementation approaches discussed in detail. Slides are subset of those covered in actual five day or three month training sessions.

Course Length: Six Hours

Course Content: Overview of Lean Fundamentals and Implementation Approach

Course Fee: See Price List. Training room and meals to be furnished by the Client. Course may be tailored to a company for an additional fee.

Max Participants: 30

Prerequisites: None

Who should attend?: Business Executives, Owners, Senior Leadership Team, Prospective Lean Team Members

Purpose: Introduce Strategic and Competitive Advantages inherent in Lean Thinking Concepts. Provide a unique implementation approach, expected results and show funding opportunities.

Benefit: Shows tremendous opportunities for process improvements and proven implementation approach which yields tremendous savings

Lean Fundamentals Seminar II

One Day Training Class

Participants will receive a broad-based overview of lean manufacturing and lean thinking fundamentals. Course includes hands on lean assembly simulation.

Course Length: Eight to Ten Hours

Course Content: Overview of Lean Fundamentals Seminar with Batch vs. One Piece Flow Hands on Simulation.

Course Fee: See Price List. Course may be tailored to a company for an additional fee

Max Participants: 24

Prerequisites: None

Topics include: Video comparisons of batch to one piece flow environments, lean industrial and process engineering analysis, standard work, job standardization, Kanban, Five S, TPM, Lean Sustaining and Implementation tips, typical results of lean implementations and videos of world class operations. Differences between Kaizens, Demand Flow and other implementation approaches discussed. Slides are subset of those covered in actual five day or three month training sessions.

Who should attend?: Business Executives, Owners, Senior Leadership Team, Prospective Lean Team members, Team Members
Purpose: Introduce Strategic and Competitive Advantages inherent in Lean Thinking Concepts. Provide a unique implementation approach, Expected Results. Show funding opportunities.

Benefits: Provides “hands on” demonstration of lean principles at work. Shows tremendous opportunities for process improvements and proven implementation approach which yields tremendous savings.

Some videotaping and pictures may be required.

Lean Fundamentals Seminar III

Two Day Training Class

Participants will receive a broad-based overview of lean manufacturing and lean thinking fundamentals. Course includes: Instruction on Lean principles, Hands on simulations. lean value stream, analyze and create a one piece balanced synchronized flow assembly line, view machine shop examples of one person to 7 or 8 machines, Lean Organizational structure, Lean materials, implementation process map review, video comparisons of batch to one piece flow environments, lean industrial and process engineering analysis, standard work, setup reduction, Layout and cell design, Line balancing, Five S, TPM overview, Kanban, change management, typical results of lean implementations and videos of world class operations.: Differences between Kaizens, Demand Flow and other implementation approaches discussed in detail. Team Building and Total Quality Exercises are woven into course fabric.

Course Length: 16 Hours

Course Content: Overview of Lean Fundamentals Seminar with Batch vs. One Piece Flow Hands on Exercise

Course Fee: See Price List. Per person plus expenses. Training room and meals to be furnished by the Client. Course may be tailored to a company for an additional fee.

Max Participants: 24

Prerequisites: Determined by company implementation approach selected.

Course Description:

Who should attend? Business Executives, Owners, Senior Leadership Team, Prospective Lean Team members, Managers, Production Control, Material Control, Purchasing, Manufacturing.

Purpose: Introduce Strategic and Competitive Advantages inherent in Lean Thinking Concepts. Provide a unique implementation approach. Provide a foundation for a pilot team to implement lean product and process improvements with some mentoring by a trained Master Facilitator.
Expected Results. Participants will leave with a thorough understanding of lean principles. The course is geared to implementation.

Benefits: Provides training and education through “hands on” demonstration of lean principles at work. Course is 60% lecture, 40% videos and hands on exercises. This course will teach you how to identify waste and techniques to eliminate it. It has tremendous opportunities for process improvements and proven implementation approach which yields tremendous savings.

Lean Fundamentals Seminar IV

Three Day Training Class

Participants will receive a broad-based overview of lean manufacturing and lean thinking fundamentals. Course includes: Instruction on Lean principles, Hands on simulations. Systems thinking simulation, Value Steam Mapping Overview, analyze and create a one piece balanced synchronized flow assembly line, view machine shop examples of one person to 7 or 8 machines, Lean Organizational structure, Lean materials, implementation process map review, video comparisons of batch to one piece flow environments, lean industrial and process engineering analysis, group technology, standard work, capacity analysis, setup reduction, Layout and cell design, Line balancing, Performance Management, Five S, TPM overview, Two bin material systems and Kanban, MBTI Styles and change management, typical results of lean implementations and videos of world class operations.: Differences between Kaizens, Demand Flow and other implementation approaches discussed in detail. Team Building and Total Quality Exercises are woven into course fabric.

Course Length: 24 Hours

Course Content: Overview of Lean Fundamentals Seminar with Batch vs. One Piece Flow Hands on Exercise

Course Fee: See Price List. Per person plus expenses. Training room and meals to be furnished by the Client. Course may be tailored to a company for an additional fee.

Max Participants: 24

Prerequisites: Determined by company implementation approach selected.

Who should attend? Business Executives, Owners, Senior Leadership Team, Prospective Lean Team members, Managers, Production Control, Material Control, Purchasing, Manufacturing.

Purpose: Introduce Strategic and Competitive Advantages inherent in Lean Thinking Concepts. Provide a unique implementation approach. Provide a foundation for a pilot team to implement lean product and process improvements with some mentoring by a trained Master Facilitator.

Expected Results: Participants will leave with a thorough understanding of lean principles. The course is geared to implementation.

Benefits: Provides training and education through “hands on” demonstration of lean principles at work. Course is 40% lecture, 60% videos and hands on exercises. This course will teach you how to identify waste and techniques to eliminate it. It has tremendous opportunities for process improvements and proven implementation approach which yields tremendous savings.

Lean Fundamentals Seminar V

Five Day Training Class

Participants will receive a broad-based overview of lean manufacturing and lean thinking fundamentals. Course includes a Kaizen Event during the class (if on site at Host Company), Overview of Lean Principles, world class videos and “hands on” simulations. Training includes systems thinking simulation, lean value stream analysis, analyze and create a one piece balanced synchronized flow assembly line, view machine shop examples of one person to 7 or 8 machines, Lean Organizational structure, Lean materials, supply chain management, implementation process map review, video comparisons of batch to one piece flow environments, lean industrial and process engineering analysis, product process flow analysis, operator analysis, group technology, standard work, job standardization, setup reduction, Layout and cell design, Line balancing, Performance Management, Five S, TPM overview, Two bin material systems and Kanban exercises, MBTI Styles and change management, typical results of lean implementations and videos of world class operations.: Differences between Kaizens, Demand Flow and other implementation approaches discussed in detail. Team Building and Total Quality Exercises are woven into course fabric.

Course Length: 35 – 40 Hours

Course Content: Overview of Lean Fundamentals Seminar with Batch vs. One Piece Flow Hands on Exercise

Course Fee: See Price List. Per person plus expenses. Training room and meals to be furnished by the Client. Course may be tailored to a company for an additional fee.

Participants: Minimum 16 – Max 35

Prerequisites: Determined by company implementation approach selected.

Who should attend? Business Executives, Owners, Senior Leadership Team, Prospective Lean Team members, Managers, Production Control, Material Control, Purchasing, Manufacturing.

Purpose: Introduce Strategic and Competitive Advantages inherent in Lean Thinking Concepts. Provide a unique implementation approach. Provide a foundation for a pilot team to implement lean product and process improvements with some mentoring by a trained Master Facilitator.

Expected Results. Participants will leave with a thorough understanding of lean principles. The course is geared to implementation.

Benefits: Real example of lean at work in the factory. Provides training and education through “hands on” demonstration of lean principles at work. Course is 40% lecture, 60% videos and hands on exercises. This course will teach you how to identify waste and techniques to eliminate it. It has tremendous opportunities for process improvements and proven implementation approach which yields tremendous savings.

Lean Advanced Seminar V

Five Day Training Class

Participants will receive adavanced training in lean manufacturing and lean thinking principles. Course includes a Kaizen Event during the class (if on site at Host Company), Detailed world class videos and “hands on” simulations. Training includes systems thinking, lean value stream analysis, analyze and create a one piece balanced synchronized flow assembly line, view machine shop examples of one person to 7 or 8 machines, Lean Organizational structure, Lean materials, supply chain management, implementation process map review, video comparisons of batch to one piece flow environments, lean industrial and process engineering analysis, product process flow analysis, operator analysis, group technology, standard work, job standardization, setup reduction, Layout and cell design, Line balancing, Performance Management, Five S, TPM overview, Two bin material systems and Kanban exercises, MBTI Styles and change management, typical results of lean implementations and videos of world class operations.: Differences between Kaizens, Demand Flow and other implementation approaches discussed in detail. Team Building and Total Quality Exercises are woven into course fabric.

Who should attend? Lean Practitioners or anyone that wants more advanced insight into the lean tools.

Purpose: Introduce Strategic and Competitive Advantages inherent in Lean Thinking Concepts. Provide a unique implementation approach. Provide a foundation for a pilot team to implement lean product and process improvements with some mentoring by a trained Master Facilitator.
Expected Results. Participants will leave with a thorough understanding of lean principles. The course is geared to implementation.

Benefits: Real example of lean at work in the factory. Provides training and education through “hands on” demonstration of lean principles at work. Course is 40% lecture, 60% videos and hands on exercises. This course will teach you how to identify waste and techniques to eliminate it. It has tremendous opportunities for process improvements and proven implementation approach which yields tremendous savings.

Course Length: 35 – 40 Hours

Course Content: Overview of Lean Fundamentals Seminar with Batch vs. One Piece Flow Hands on Exercise

Course Fee: See Price List. Per person plus expenses. Training room and meals to be furnished by the Client. Course may be tailored to a company for an additional fee.

Participants: 16 Min – 35 Max

Prerequisites: Determined by company implementation approach selected.

Total Company Wide Quality Control Class

Review and overview of Pareto charts, cost of poor quality, fishbone, flow charts, check sheets, histograms, CPK, SPC, Problem solving, Simple Control Charts, Brainstorming, Effective Meeting Tools

Who should attend?: Operators, admin folks, managers

Purpose: Train participants in overview of various TQ tools

Benefits: Participants learn how to problem solve and organize and prioritize decision-making

Course Length: 1-2 days

Course Content: Introduction and practice with TQ tools

Course Fee: TBD Course may be tailored to a company for an additional fee

Max Participants: 30

Value Stream Mapping

Students bring a real process to the class to be analyzed and mapped. Students should include people that live the process and at least one person that does not.

Course Length: One day to two weeks

Course Content: Value Stream Mapping Process techniques. Teach and hands on analysis of problems, opportunities to identify waste, critical data driven inputs and outputs identification.

Course Fee: TBD. Course may be tailored to a company for an additional fee

Max Participants: 24 (3 to 6 person teams)

Who should attend? Anyone in the company

Purpose: To utilize a “systems thinking” approach to analyze any process – shop floor, administrative, engineering, healthcare

Benefits: Identifies waste in processes, project prioritization to the strategic business plan

Training Within Industry – TWI

Students bring a real process to the class to be analyzed and mapped. Students should include people that live the process and at least one person that does not.

Course Length: Varies

Course Content: Job Instruction, Job Methodology, Job Relations

Course Fee: TBD. Course may be tailored to a company for an additional fee

Max Participants: 24 (3 to 6 person teams)

Who should attend? Supervisors and Managers

Purpose: To train shop floor and administrative employees

Benefits: Basis for standard work, helps pass audits, employee development