1.4 Organizational Skills

Lean Boot Camp

Overview:

The Lean Boot Camp is an intensive 4-month training program designed for middle managers, supervisors, and team leads who will play a crucial role in deploying lean tools within their organizations. This program begins with a commitment from top management to transform the organization into a lean operation, emphasizing the cultural transition necessary for effective implementation. Participants engage in 9 sessions, each lasting eight hours, where they explore various lean tools and techniques. Additionally, they will conduct a kaizen event at their home company, applying lean principles in a practical setting, and will have the opportunity to take the SME Lean Bronze Certification test at the end of the training.

Key Benefits: 

• Earn SME Lean Bronze Certification, enhancing professional credentials.
• Understand lean principles to drive organizational transformation.
• Participate in a kaizen event for hands-on experience with lean tools.
• Develop skills for leading lean initiatives and fostering continuous improvement.

Course Objectives:

• Understand the principles of lean transformation and cultural change.
• Apply lean methodologies to improve efficiency and reduce waste.
• Facilitate lean initiatives within their organization effectively.

Duration:
4 months (includes 9 eight-hour sessions)

Certification Notes:
Participants will have the opportunity to take the SME Lean Bronze Certification test upon successful completion of the program.

Enrollment:
Click the "Send a Request" button below to learn more about the course details and schedule a consultation with our expert.

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Principles of Lean Manufacturing (Lean 101)

Overview:

Principles of Lean Manufacturing (with live simulation) is an overview class that provides a foundation for all other classes in the series. Participants begin by manufacturing various assemblies in a traditional manufacturing setting. The results of the first simulation round will provide the basis for continuous improvement through the application of lean manufacturing principles. Participants will learn to identify the 8 wastes in manufacturing. This course combines lectures with hands-on simulations, teaching key concepts such as standardized work, workplace organization, visual controls, setup reduction, batch size reduction, point-of-use storage, quality at the source, workforce practices, and pull systems. Each of these principles is designed to eliminate waste in the manufacturing processes.

Key Benefits:

• Develop a foundational understanding of lean manufacturing principles
  
• Gain practical experience through live simulations
  
• Learn to identify and eliminate the 8 wastes in manufacturing

Course Objectives:

• Understand the core principles of lean manufacturing
  
• Apply lean techniques to improve manufacturing efficiency
  
• Learn methods for implementing standardized work and visual controls

Duration:
6 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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Principles of Lean Office (Lean 101 for Office)

Overview:

The full-day Lean Office training workshop combines classroom-style learning with an interactive live simulation, where participants assume the roles of managers and workers within a company. During the session, participants learn lean definitions and techniques tailored for office environments. They engage in activities within a traditional office setup, using forms, calculators, and established procedures. The workshop involves transforming the office through three "stages" or "days," where improvements are implemented at the end of each stage. By applying lean techniques, participants will witness the transformation of office work from a disorganized and slow process to a more efficient, effective, and predictable workflow.

Key Benefits:

• Gain practical experience in applying lean principles to office processes
  
• Experience the transformation of workflows through hands-on simulations
  
• Learn to identify and eliminate waste in an office environment

Course Objectives:

• Understand key lean definitions and techniques relevant to office settings
  
• Implement lean practices to enhance office efficiency and effectiveness
  
• Analyze the impact of lean transformations on workflow predictability

Duration:
6 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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Workplace Organization (5S)

Overview:

This course provides shop floor workers with an introduction to the basics of the five S's: Sort, Set in Order, Shine, Standardize, and Sustain. These cleaning and straightening activities form the foundation for all workplace improvements, making this training particularly valuable for operators in manufacturing environments, pilot teams, and Lean Manufacturing implementers. By establishing a clean and organized workplace, participants will learn how to create a Lean environment that enhances efficiency, reduces waste, and promotes a culture of continuous improvement.

Key Benefits:

• Understand the five S's and their role in workplace organization
  
• Enhance workplace efficiency and productivity through effective cleaning and organization techniques
  
• Foster a culture of continuous improvement within the organization

Course Objectives:

• Learn the principles and practices of the five S's
  
• Develop skills to implement and sustain a clean and organized workplace
  
• Recognize the impact of workplace organization on overall operational efficiency

Duration:
6 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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Total Productive Maintenance (TPM)

Overview:

This course equips participants with a proactive approach to maintain machines and equipment at peak productivity levels. Students will gain a comprehensive understanding of Total Productive Maintenance (TPM) and the five major roles essential for effective deployment. Emphasizing the importance of TPM, the course will highlight how it increases overall equipment effectiveness (OEE) and helps prevent production interruptions, leading to reduced batch sizes and enhanced equipment performance. Participants will also explore the 8 pillars of TPM, providing them with the knowledge needed to implement TPM principles effectively.

Key Benefits:

• Gain insights into the principles and benefits of Total Productive Maintenance
  
• Understand the five major roles in TPM deployment
  
• Learn how to increase overall equipment effectiveness and minimize production interruptions

Course Objectives:

• Develop a deep understanding of the eight pillars of TPM
  
• Recognize the impact of TPM on reducing batch sizes and improving equipment performance
  
• Acquire skills to implement TPM strategies in the workplace

Duration:
6 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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Set-up Reduction/Quick Changeover (SMED)

Overview:

This course teaches the fundamental principles of set-up reduction, focusing on the Single Minute Exchange of Dies (SMED) methodology. The instructor will clearly define what set-up entails and discuss the reasons for and barriers to reducing set-up time. Participants will learn how to apply SMED principles to any type of set-up or industry, enabling them to streamline processes and enhance operational efficiency.

Key Benefits:

• Understand the fundamental concepts of set-up reduction
  
• Identify common barriers to reducing set-up time
  
• Learn how to apply SMED principles effectively across various industries

Course Objectives:

• Gain a clear understanding of the standard methodology for set-up reduction
  
• Develop skills to analyze and improve set-up processes
  
• Create strategies to implement quick changeover techniques in the workplace

Duration:
6 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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Standardized Work & Cellular/Flow Manufacturing

Overview:

This hands-on course teaches participants how to effectively link and balance manufacturing operations to achieve reduced lead times, minimized work in process, optimized floor space usage, and improved productivity. Through interactive instruction, the course will guide participants through the 5-step process for designing and implementing work cells, applicable to both assembly and fabrication applications.

Key Benefits:

• Learn how to create efficient work cells that streamline operations 
  
• Reduce lead times and improve overall productivity 
  
• Optimize the use of floor space and minimize work in progress 

Course Objectives:

• Understand the principles of standardized work and its role in manufacturing 
  Master the 5-step process for designing and implementing work cells 
  Apply cellular and flow manufacturing techniques to real-world scenarios 

Duration:
6 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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Shingo Workshops

Overview:

The Shingo Workshops are designed to help organizations drive a culture of excellence by leveraging the Shingo Model. This comprehensive workshop series encompasses 6 distinct workshops, beginning with the Discover Excellence workshop, which serves as a prerequisite. This foundational workshop introduces participants to the core concepts of the Shingo Model and its 10 Guiding Principles. The subsequent workshop, Systems Design, focuses on understanding what constitutes a system, effective mapping techniques, and ensuring continuous improvement within those systems.

The next three workshops – Cultural Enablers, Continuous Improvement, and Enterprise Alignment – can be attended in any order, allowing participants to dive deeper into the Shingo Model. These workshops enhance understanding of the ideal behaviors necessary to achieve outstanding organizational results. Finally, the Build Excellence workshop acts as the capstone, synthesizing learnings from the previous five workshops and equipping participants with the skills to create systems that drive desired behaviors and consistent outcomes.

Key Benefits:

• Gain a comprehensive understanding of the Shingo Model and its principles.
• Learn to design systems that promote continuous improvement and excellence.
• Develop the ideal organizational behaviors necessary for outstanding results.
• Collaborate with participants from various backgrounds to enhance learning.

Course Structure:

The Shingo Workshops series consists of six workshops:

• Discover Excellence: Foundational workshop on the Shingo Model and guiding principles.
• Systems Design: Understanding systems and how to ensure their continuous improvement.
• Cultural Enablers: Exploring behaviors that foster a culture of excellence.
• Continuous Improvement: Techniques and methodologies for driving improvement initiatives.
• Enterprise Alignment: Strategies for aligning organizational goals and activities.
• Build Excellence: Capstone workshop integrating all learnings to develop effective systems.

Duration:
8 hours for each workshop

Certification Notes:
Participants will receive a certificate of completion for each workshop upon successful participation.

Enrollment:
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Toyota Kata is a transformative approach to organizational improvement that emphasizes the development of a continuous improvement culture through structured routines. Rooted in the principles of Lean Manufacturing, this methodology enables organizations to systematically tackle challenges and achieve strategic objectives. By focusing on “kata,” or structured practice routines, employees learn to think scientifically and engage in problem-solving, fostering a mindset geared toward sustained performance enhancement.

The Toyota Kata training program offers a practical framework for participants to learn and apply these concepts effectively. By engaging in hands-on activities and real-world simulations, attendees will gain the necessary skills to implement continuous improvement initiatives within their teams and organizations.

The following Toyota Kata training courses are available:

• Kata in a Box
• Kata Domino Challenge

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Kata in a Box

Overview:

Kata in a Box is a comprehensive two-day training program designed to introduce participants to the fundamental concepts of the "starter kata" methodology. The first day focuses on understanding the Kata principles through a manufacturing process simulation, allowing participants to grasp the application of these concepts in a practical setting. The second day dives deeper into the process by teaching participants how to create an A3 report, which incorporates data acquisition specific to the customer's operations. The training culminates in a half-day coaching session, where participants receive personalized guidance on applying their learning and utilizing the A3 effectively in real-world scenarios.

Key Benefits:

• Gain a solid foundation in Kata methodology and its applications in continuous improvement.
• Experience hands-on learning through a manufacturing simulation.
• Develop skills in data acquisition and A3 report creation tailored to operational needs.
• Receive live coaching to reinforce learning and support implementation in the workplace.

Duration:
8 hours: 2 sessions, 4 hours each

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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Kata Domino Challenge

Overview:

The Kata Domino Challenge is a one-day training program designed for organizations of all types, regardless of their products or services. This engaging course introduces participants to the concept of “starter kata” and guides them through the process of building an A3 report. The A3 serves as a framework for tracking each cycle of organizational learning and identifying areas for improvement.

To reinforce these concepts, participants will engage in a creative challenge that involves arranging a domino pattern, symbolizing the interdependence of organizational processes. This hands-on activity emphasizes the importance of systematic thinking and encourages incremental improvements within the organization.

Key Benefits:

• Gain practical experience in using kata for organizational learning.
• Learn to create an A3 to track progress and improvements.
• Foster a culture of continuous improvement through collaborative challenges.

Course Objectives:

• Understand the fundamentals of starter kata and its application in various settings.
• Develop skills in creating and utilizing A3 reports for process improvement.
• Implement incremental improvements based on organizational learning cycles.

Duration:
8 hours

Certification Notes:
Participants will receive a course completion certificate upon successful completion.

Enrollment:
Click the "Send a Request" button below to learn more about the courses and schedule a consultation with our expert.

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