Typical Management Training Sequence (Manufacturing tract shown) :

 

Executive Lean/World Class Overview - One day

This is a high level overview of the business waste elimination tools of Lean and an introduction to the implementation pre-requisites for management. It includes a batch production versus flow production simulation and a discussion of how implementing Lean impacts an organization's financial performance.

Agenda:

    • Why We are Here-Proof of the Need
    • Customer Satisfaction and Waste Elimination
    • Management World Class Enterprise Implementation Prerequisites
    • 5S: Paving the Approach
    • Team Building/Problem Solving/Error Proofing
    • Total Productive Maintenance (TPM)
    • Process Cells
    • Setup Reduction
    • Inventory Kanbans
    • One-Piece Flow Simulation
    • Accounting for World Class Operations

 

How to Prevent Lean Implementation Failures: 10 Reasons Why Failures Occur - Half day

 

When a Lean implementation fails in an organization, the responsibility rests with management. The goal of this session is for the organization's Leadership Team to be able to understand and identify the implementation barriers, road blocks, and show-stopping issues that may arise within the company during their Lean Implementation effort.

 

Agenda:

    • Lack of Top Down Management Support
    • Lack of Communication
    • Lack of Middle Management/Supervisor Buy-in
    • Not Understanding that this is About Developing Your People
    • Lack of Customer Focus
    • Lack of Improvement Measurements
    • Lack of Lean Leadership
    • People Measures/Goals which are not Aligned with Implementation Goals
    • Using Kaizen Events as the Sole Improvement Mechanism
    • Bonus Pay Systems Where the Only Measure is Company Profitability 
 

Policy Deployment, Lean as a Business System - Four days

 

This 10 step, four-day management session integrates the organization's goals with Lean and then plans for the deployment of this "system" throughout the organization. The ten steps are:

1.   Defining Mission, Vision, and Behavioral Expectations

2.   Organization's goals ... Operating Income, Cash Flow, Revenue, ROIC, and Safety

3.   Brainstorm opportunities to achieve goals

4.   Scope, value, and prioritize opportunities

5.   Rate and validate if opportunities will achieve company goals with available resources

6.   Conduct a reality check

7.   Cascade company goals into operational metrics & develop "Bowling" chart

8.   Develop Lean Implementation plan

9.   Problem solving, error proofing, and counter measures

10.   Deployment follow up-How to conduct monthly business reviews

 

Optional :

 

Accounting for Lean: What Operations Needs to Know - Two hours

 

How Lean and Six Sigma Work Together - Two hours

 

Lean Supply Chain (Lean must already be implemented in the organization)- Two Days