Lean Tools A-Z

5S and Standard Work

5S is a foundational Lean tool. This course will create an awareness of how a clean organized work area impacts productivity, quality, attitudes, and safety in the workplace. Learn how to create standardized procedures to maintain and control an organized workplace using visual controls. Learn how to develop a plan to sustain including processes to audit.

5S Workplace Organization

Participants will be introduced to and practice lean workplace organization 5S principles: Sort, set in order, shine, standardize, and sustain through a simulation.

Cellular Flow

This session explores the physical flow of materials and the value added steps in a production environment. Participants will also learn how to design a manufacturing cell by applying a five-step process, as well as how to identify key wastes reduced by cellular flow.

Facilitation skills for lean champions

What are the responsibilities of a project leader? What is the role of a facilitator? What are the challenges of trying to do both? By the end of training, participants will be able to answer these three questions. Participants will also practice basic facilitator skills including how to stay neutral, paraphrase, evaluate and debrief. Participants will also explore effective processes and tools to accomplish the agenda as well as how to deal with difficult behaviors in meetings including sidebars and dominating personalities.

Hoshin planning & strategy deployment

Hoshin Planning is a guidance and delivery system for getting the right things done. Participants will learn how to Increase effectiveness in organizational planning through the utilization of Hoshin Planning tools. Upon completion participants will be able to identify the key characteristics of Hoshin Planning as well as differences with other planning processes. Participants will develop an annual company plan and an action plan and also standardized work for check.

Kanban and Pull Systems

Increase throughput, decrease inventory, and decrease operating expense. A pull can help you achieve all of these goals. A pull system is an information system for controlling and improving the flow of materials and information. Resources are then allocated based on actual consumption, not forecasted demand. Participants will learn about the differences between a pull and push system as well as pull system tools including finished goods supermarkets, pull rates, kanban cards and order points.

Lean office simulation

Participants will be introduced to the “8 wastes” and lean principles used to reduce these wastes in an office setting. Participants will practice implementing these tools to improve the flow of value in an office simulation.

Manufacturing Simulation

Participants will be introduced to the “8 wastes” and Lean principles used to reduce these wastes in a manufacturing setting. Participants will practice implementing these tools to improve the flow of value in an airplane manufacturing simulation.

Poke-yoke » error-proofing

Error-proofing is a simple way to ensure that a certain kind of error, one that people are prone to make repeatedly, can no longer happen. In this session, participants will be introduced to various error-proofing tools as well as when and how to apply these tools and the expected results.

Project planning

What are some of the challenges you have faced in managing projects and getting them done? We can help you increase your effectiveness/efficiency in managing projects through the utilization of plan-do-check-adjust, team charters and A3’s. By the end of the training participants will be able to apply plan-do-check-adjust to managing projects, use tools to get projects off to a good start, use tools to implement a project plan and monitor progress, and identify important steps in closing a project.

SMED Principles (single minute exchange of die)

A reduction in lead time, increased productivity, reduction of WIP (Work in Process), improved quality and better space utilization. These are just some of the benefits SMED can help you achieve. In this course, participants will explore the four basic functions of a changeover operation as well as how to classify internal and external setup elements. This session utilizes hands on activity to collect data and analyze the opportunity that exists to decrease changeover time.

Total productive maintenance (tpm)

TPM is a process that maximizes the productivity of equipment for its entire life cycle and will extend the life of the equipment. Through the participation of all employees, TPM create an environment that encourages improvement efforts in safety, quality, cost, delivery, and creativity. Participants will explore the benefits of TPM as well as how to implement a TPM plan as well as how to collect and analyze Overall Equipment Effectiveness (OEE) data.

Value Stream Mapping basics

Participants will be able to create a visual map of the process steps in the current flow of value. The current state map will be used to create a future state vision and an action plan for achieving the future state.

Value Stream Mapping current state

Learn how to map the flow of value though an organization. During training, participants will identify steps and tools for creating a current state value stream map. Participants will also create a basic value stream map based on a case study and a company process. Learn how to collect metric data and how to identify possible implementation challenges and brainstorm strategies for overcoming them.

Value Stream Mapping future state & metrics

Learn how to map the flow of value though an organization. During training, participants will identify steps and tools for creating a future state value stream map and create a future state value stream map based on a company process. Participants will identify kaizen bursts required to realize the future state and determine the appropriate lean metrics to track improvement.

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