Lean Tools
Kaizen Breakthrough Tools
Assessment & Planning
Awareness Training
1. Lean Executive Introduction (LEI) – Lean Executive Introduction -
Two days of training, including exercises introduces management to Lean.
2. Visualizing a Lean Strategy- Value mapping
The Current State map shows how the 7 Wastes affect your production processes. The Future State map defines your Lean Strategy and kaizen calendar.
3. Introduction to Lean – Workforce Orientation for Lean Transformation
Employees are given basic training in the goals, tools, and concepts of Lean.
Breakthrough Improvement Event
4. LBK LeanBreakthru Kaizen - Rapid improvement of productivity, space, throughput, lead-time, inventory and other areas in a 5-day shop floor focused event. The following topics are implemented based on area of focus:
* Standard Work The Foundation of Lean Manufacturing Takt Time, Work Sequence, and Standard WIP are used to make the most efficient combination of manpower, material, and machinery.
* Material Presentation Minimize Inventory and Prevents Shortages Implementing tools of the Pull System, such as Kanban, Supermarkets, Kitting, 2-Bin System, and the Waterspider
* Jidoka Autonomation for Abnormality Management, preventing abnormality reoccurrence by:
- Mistake proofing of equipment, visual management tools, and low-cost automation are used to identify and prevent errors and improve productivity.
- Separating the man from the machine
* Production Leveling Smoothing Out Mixed-model Production Averaging the mix and volume of work minimizes variation of the production load and makes planning possible on a daily and hourly basis.
5. LOK Lean Office Kaizen
Use kaizen to create engineering cells, streamline information flow from customer order through shipment and invoicing, and eliminate the less visible but equally costly wastes of the office.
6. SMED Single Minute Exchange of Dies
The set-up time reduction module offered as GKW or training course focuses on quick changeover as a tool for inventory reduction, lead-time reduction, and capacity improvement.
7. TPM Total Productive Maintenance
Focus on the 5 Pillars (Clean to Detect to Correct to Prevent to Protect) to increase equipment effectiveness and uptime.
8. Lean 3P Design Lean Production Preparation Process
Define a production process based on Lean principles (JIT, Jidoka, 7 Wastes) and create production equipment inexpensively in-house.
Lean 3P - Breakthru Process Design Example
9. Lean 4P Design Product & Production Preparation Process
Design products using tools such as Voice of Customer, DFM/DFA, QFD, FMEA and others to make products that meet GembaSigma standards.
Lean 4P - Breakthru Product Design
10. SML - Senior Management Leadership
Aligning business strategies & projects to exceed company goals & create a direct link for corporate objectives to shop floor daily activities.
Managing Lean Implementation
11. TTT – Train the Trainer
Developing in-house trainers by teaching how to teach the basic modules, avoid common pitfalls, and resolve conflicts, and build positive team dynamics.
12. KPO – Running a Kaizen Promotion Office
Learn how to establish and manage an effective Kaizen Promotion Office that will implement Lean to achieve company goals.
13. MDI – Managing for Daily Improvement
Train plant managers, area managers, supervisors and team leaders in their new roles for daily improvement.
14. LET - Lean Excellence Tour
Spend a three days learning from world-class Lean factories in the USA, including Toyota.
Advanced Lean Tools
15. LeanBreakthruSigma™ - Achieving 6-Sigma Level Quality
– Improving quality by reducing variation at the speed of Kaizen. Implement levels of process control to approach world-class quality (3.4 Defects Per Million).
16. Lean Accounting - Implement an Enterprise Management System that reflects the financial performance of your organization based on Lean principles and promotes rapid persistent improvement.
– Incorporate an accounting system that views every transaction as waste.
- Improve profits by eliminating standard cost systems that prevents potential sales by incorporating Value Stream Costing.
- Create Value Stream P & L statements to understand an manage your enterprise.
Lean Accounting - Lean Enterprise Management
17. Lean Supply Chain Development - Expand your Lean transformation to include your supplier base.
- Involve suppliers in your Lean Strategy to reduce inventory, lead-time, to ensure On-time delivery and prevent quality problems while continuously driving down cost.
- Involve distributors by implementing Lean distribution principles to stream-line the replenishment of materials and services throughout the entire value chain.
Lean Distribution - Synchronize your Value Chain material replenishment process
