Lean Consulting & Training

Provide assessment of your key business processes, prioritize area of focus based on your goals, and lead/facilitate Lean events to implement change ... working with you to fix key problems! 

We will also provide training where nominated employees attend either virtual or in-person sessions while coaching is provided as they fix business related issues. Improvements are aligned to your business goals to increase productivity and market share. By decreasing waste and implementing standard work, you can better predict the outcome of every process every time while reducing business cost.  

Overview of Lean concepts will highlight how this methodology enables businesses to improve process efficiency resulting in increased revenue and quality with a focus on customer satisfaction.

Operational Excellence Framework & Assessment - Introduction to basic Lean concepts while working through your business assessment to establish a baseline. The assessment can be revisited yearly to see growth!

 Session to create the strategy plan for your business. Create Mission and Vision statements and teach Hoshin Kanri (strategy planning methodology). Business leaders will walk away with a plan which identifies the areas of focus, how to measure the goals, and actions to reach the targets.

Teach 7 Lean concepts which will get the team started in learning about Lean and implementing small-scoped improvements. Upon completion of this training program and application of Lean concepts, a certificate will be awarded. This program includes:

•  5S: Concept to create a clean, well ordered, and disciplined work environment. Will also cover how to hold a 5S event.
• Waste Elimination: Learn about an effective way to identify non-value added processes and activities and how to create countermeasures to resolve them.
• Data Collection & Graphs: Learn about basic concepts surrounding data, effective data collection techniques and the best graphs to display the data.
• PDCA: Plan, Do, Check, Act is a four-step model for carrying out change.  
• Fishbone Diagram: Learn how to effectively brainstorm potential issues using the Fishbone template which is a basis for problem solving. 
• Basic Problem Solving: Understand how to identify solutions using this six-step approach and use of template.
• Standard Work: Standard Work is a means of establishing precise procedures to make products in the safest, easiest, and most effective way based on current technologies.

Team members are now learning and using intermediate Lean concepts on their improvement initiatives. Upon completion of this training program and application of Lean concepts, a certificate will be awarded. This program includes:

• Gemba: Understand what Gemba is and how to effectively integrate this concept into a daily routine to understand the place where value is created.
• Visual Management:  Learn about the various types of visual management and how to set up visual boards to monitor performance.
• Change Management & Creating a Lean Culture: Understand how to setup the framework and deploy changes in the four-phased approach.
• Lean Events - JDI, Planning Session & Long-term Improvement: These 3 Lean event types are reviewed along with supplemental templates which are used during improvement initiatives.
• Value Stream Mapping: This session focuses on a fundamental Lean tool to understand performance of processes via this diagramming method.
• Influencing: Identify how to influence others for effective change management.
• Autonomation & Andon: Learn how to deploy automation with a human element to increase quality.
• Control Plans: Understand what's included in closing out an improvement initiative and formally handing it over to the process owner.

Teams are now focused on complex and systemic issues, working with cross-functional groups. Upon completion of this training program and application of Lean concepts, a certificate will be awarded. This program includes:

• Daily Management: Incorporate basic and intermediate concepts to create a visual daily management process with regular cadence to sustain process discipline.
• Kaizen Event: Learn how to plan and hold a Kaizen event to make rapid improvements back to the business within a week.
• Push/Pull & Heijunka: Learn about these concepts to manage flow and work through a simulation to apply the concepts, then see how to level load your process.
• Line of Balance: Apply this Lean tool and discuss during your daily Gemba to monitor product status, especially when process steps are external to the line. 
• Cell Design: Proper planning using the Cell Principles and Guidelines will ensure the best layout before installation.
• Root Cause & Corrective Action (RCCA): Spend time learning about how to find and fix true root problems using the 8D methodology. 
• Total Productive Maintenance (TPM): Learn how to setup and implement a maintenance program for all equipment and how to monitor the effectiveness.
• Production Preparation Process (3P): This Production Preparation Process Lean concept enables a team to proactively plan a new layout or process through a series of steps including brainstorming, trystorming, and documenting.

Additional items are provided upon request:

• Improvement Database: Define requirements to setup a workflow, a database system, and metrics to track improvements. Monitoring improvements and realizing savings will ensure a sustainable program. 
• Showcase system: Set up a system to share and leverage improvements while providing team members to practice presentation skills.
• Savings Validation: Provide guidance to establish definitions and how to calculate savings for improvements.
• DOT Game Simulation: Run an in-person simulation to recognize waste while teaching many Lean concepts. This is a great team building and fun exercise.
• Lean program: Set up a Lean program within your business, training champions to oversee improvements, drive closure, and coach others, allowing a sustainable in-house effort.