Lean Applications
Lean manufacturing is all about
eliminating waste to help the efficiency
and effectiveness of your operations.
When we say waste, we mean defects, overproduction, downtime, transportation, inventory, motion, extra processing, and unused talent. These are all getting in the way of your business’s operational excellence. We can help!
5S in Action
Check out these side-by-side comparisons of workspaces before and after 5S is applied.
Our Lean Applications Training Program
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Lean Sigma is a data-driven, structured process for identifying and resolving complex, systemic performance gaps. The Lean Sigma (DMAIC) approach standardizes project management to deliver performance improvements that benefit the bottom line financials and boost customer satisfaction. Green Belt Plus training introduces the Define, Measure, Analyze, Improve and Control (DMAIC) methodology.
Minimum/Maximum Class Size: 8-16 people.
Applying these concepts and skills will allow you to:
Facilitate Lean Sigma teams through the DMAIC process.
Understand what tools to use for different types of projects.
Suggested Attendees: Engineering and Quality Technicians, managers, Continuous Improvement facilitators and/or select individuals who will interpret data from project teams, serving as Project Champions or Project Leaders.
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Designed to pull together past Green Belts and Green Belt Facilitators, Green Belt Refresher Training allows participants to discuss past projects, successes or failures, tools, and more. The training ultimately helps improve the skills of the Lean Sigma project facilitation.
Minimum/Maximum Class Size: None.
Applying these concepts/skills will allow you to:
Help trainers instruct Lean Sigma teams through the DMAIC process.
Help trainers instruct Lean Sigma teams to understand what tools to use at each step of the project.
Suggested Attendees: Engineering and Quality Technicians, Managers, Continuous Improvement facilitators and/or select individuals who have served as Project Champions, Facilitators, Leaders or team members of DMAIC projects.
Prerequisites: Yellow Belt Training, DMAIC Basics Training and Green Belt Plus Training.
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Yellow Belt training is conducted in short segments during Lean Sigma project implementation. This course gives team members an overview of the DMAIC process, Toll Gate Review, roles of team members, and the tools used in each step of the process. The team is trained in real-time during each phase of the project.
Minimum/Maximum Class Size: None.
Applying these concepts/skills will allow you to:
Help trainers instruct Lean Sigma teams through the DMAIC process.
Help trainers instruct teams to understand what tools to use at each step of the project.
Suggested Attendees: Engineering and Quality Technicians, Managers, Continuous Improvement facilitators and/or select individuals who will be leading, facilitating, or serving as project members.
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Yellow Belt Train-the-Trainer is designed to instruct facilitators on how to teach the Yellow Belt Training material.
Minimum/Maximum Class Size: None.
Applying these concepts/skills will allow you to:
Help trainers instruct Lean Sigma teams through the DMAIC process.
Help trainers instruct Lean Sigma teams to understand what tools to use at each step of the project.
Suggested Attendees: Engineering and Quality Technicians, Managers, Continuous Improvement facilitators and/or select individuals who will be interpreting data from project teams, serving as Project Champions or Project Leaders.
Prerequisites: Yellow Belt Training.
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This training is implementation-based, designed for those who are ready to create current state and future state maps in their areas. The Value Stream Mapping tool is introduced in a hands-on manner, so participants can successfully use Value Stream Mapping in their areas. Participants will gain the ability to “see the flow” of value stream and design an improved value stream—the future states.
Minimum/Maximum Class Size: None.
Applying these concepts/skills will allow you to:
Develop a current state Value Stream Map.
Develop a current state Value Stream Map.
Design an improved Value Stream-Future State.
Suggested Attendees: Product/Service Managers, supervisors, Support Staff members, Continuous Improvement Facilitators, and select individuals who will lead the implementation of quick changeovers of machines or processes.
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In Japanese, the word ‘Kaizen’ means “good change.” The Kaizen Event is a project activity that focuses on creating rapid improvements in a specific area. Functional Teams are identified to deliver rapid results (typically between 2-3 days) and improve processes, products, and services within their areas. Teams are also taught how to maintain these improvements over time.
Minimum/Maximum Class Size: None.
Applying these concepts / skills will allow you to:
Lead fast-action project teams through the Kaizen Event (Blitz) approach.
Use simple tools to guide teams toward their project objectives.
Guide Sigma teams through the DMAIC process.
Suggested Attendees: Product/Service Managers, Continuous Improvement Facilitators and/or select individuals who will implement fast-action project teams, serving as Project Champions, leaders, and facilitators for continuous improvement.
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Process Optimization uses a focused, Kaizen approach to identify and document the current state of any process. Teams develop future states by removing non-value-added activities, processes, or documentation. Teams also create corresponding processes and apply the PDCA Continuous Model to create efficiencies through the use of the Suggestion System. Evaluations of cycle time, wasted motion, and more are conducted through each phase of optimization. This training is relevant to service and manufacturing functions.
Minimum/Maximum Class Size: None.
Applying these concepts and skills will allow you to:
Optimize processes relative to cycle and throughput time, safety, quality, delivery, and productivity.
Create and implement future states of processes based upon internal and external customer’s needs.
Suggested Attendees: Select individuals, teams, or Continuous Improvement Facilitators who will lead or participate in process optimization.
Prerequisites: Fundamentals of Process Documentation, Implementing Standard Work Procedures and Ground Zero (strongly recommended).
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SMED stands for Single-Minute Exchange of Die. The SMED system is a theory, and a set of techniques, that make it possible to perform equipment setup and changeover operations in under 10 minutes. Originally developed to improve die press and machine tool setups, SMED principles can apply to changeovers in all types of processes. With this course, you will learn how to lead a SMED team within your own department.
Minimum/Maximum Class Size: None
Applying these concepts/skills will allow you to:
Instruct and facilitate Quick Changeover teams through an eight-module training series.
Help teams understand what tools to use when implementing SMED concepts.
Suggested Attendees: Continuous Improvement facilitators and select individuals who will lead the implementation of quick changeovers of machines or processes.
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Using common lean tools through a series of Kaizen Events, this training module outlines a step-by-step process for balancing workload. Improved states are "locked-in" by using simple Control plans and Standard Work Procedures.
Minimum/Maximum Class Size: None.
Applying these concepts/skills will allow you to:
Use a step-by-step approach to optimize processes through Continuous and Single Piece Flow methodologies and supporting applications.
Carry out Standard Work Procedures and Kanban to achieve balanced workloads.
Learn how to use and apply Measuring Systems Analysis, Control Plans, Process Metrics, Reaction Plans and Standard Work Procedures.
Suggested Attendees: Any project leader, team leader, or Continuous Improvement Facilitator.
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5S Implementation helps teams by using Kaizen events. The training follows a 4-week implementation plan to better improve workplace organization. 5S Surveys are conducted to create action plans for sorting, painting, labeling, and standardizing within teams. 5S helps set the standard for excellence throughout the team and the entire organization. Employees are taught how to organize and maintain their work area—all to improve workplace efficiency, effectiveness, and safety.
Minimum/Maximum Class Size: None.
Applying these concepts/skills will allow you to:
Describe and implement the five elements (5S) of workplace organization.
Use taping and labeling guidelines to demonstrate workplace organization concepts and theories.
Assess work areas to a 5S Workplace Organization survey.
Suggested Attendees: All Employees.
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This application establishes an understanding of Workplace Organization, “to designate a place for everything and ensure that everything is in its place”. The 5 Basics of Workplace Organization also sets the standard for excellence throughout the organization. Employees are taught how to organize and maintain their work area—all to improve workplace efficiency, effectiveness, and safety.
Minimum/Maximum Class Size: None.
Applying these concepts/skills will allow you to:
Describe the five elements (5S) of workplace organization.
Use taping and labeling guidelines to demonstrate workplace organization concepts and theories.
Assess work areas to a 5S Workplace Organization survey.
Suggested Attendees: All Employees.
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Kanban is a simple, effective “pull” system used to achieve the just-in-time inventory philosophy. This process includes the allocation of designated storage locations and the visual identification of stock-keeping units. A highly visible Kanban board (or electronic board) helps end-users monitor the material requisitions and delivery system. Planners and buyers can focus on forecasting and supplier management issues. This training is applicable to Service and Manufacturing functions that need to control raw, work-in-process, and finished goods materials.
Minimum/Maximum Class Size: None.
Applying these concepts / skills will allow you to:
Identify and choose what Kanban level works best to manage various types of inventory.
Create simple SKU and trigger cards for material replenishment or production.
Develop implementation strategies and plans
Suggested Attendees: Select individuals, teams, or Continuous Improvement Facilitators who will lead or participate in the process of visualizing and controlling inventory.
Prerequisites: Fundamentals of Process Documentation and Implementing Standard Work Procedures. Participants should also have a strong understanding and working knowledge of Microsoft Word and Excel.
Learn More About All of Our Services
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Our Core Implementation is designed to help transform your company culture and support your teams toward operational excellence in as little as 90 days.
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This 3–6-month timeline delivers a process discipline culture that sustains gains in safety, quality, delivery, cost, and productivity at all levels of the organization. This approach engages everyone in the organization to speak the same language and drives towards the common vision and goals.
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Dynamic Documentation is documenting and training best practices through engaging training videos. This method helps reduce training time for critical policies and procedures. While capturing key elements of your company’s processes, equipment, cells, software, and safety procedures, we can help you take your training to the next level.
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Lean manufacturing is all about eliminating waste to help the efficiency and effectiveness of your operations. When we say waste, we mean defects, overproduction, downtime, transportation, inventory, motion, extra processing, and unused talent. These are all getting in the way of your business’s operational excellence. We can help!
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We offer a 1-day or 2-day experiential workshop as well as a brand new, creative 4-hour virtual workshop. All of our workshops apply the fundamentals of CI, Lean, & Quality. We get everyone in your organization aligned to speak the same language while making continuous improvement fun and engaging.
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This training provides attendees with the necessary skills for planning/preparing, conducting, and reporting internal audits in a business environment. Internal audits are an ISO 9001:2015 / IATF 16949:2016 requirement and must be conducted by qualified personnel.
This course is an ideal starting point toward understanding what is needed to properly conduct internal audits.
Let’s Talk It Over!
Talk with one of our specialists to help you get the most out of your business.