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All of the following training courses have been designed by Seven Pines Consulting Group specifically to enable a company’s self-sufficiency. The sequence of the coursework is structured to provide critical internal skills and knowledge at a level appropriate to the capability of the specific organization while also guiding the improvement process. All material can be customized to meet the unique needs of the individual or organization. Level One: Getting Started > Clear Focus Lean Assessment and Goal Setting Tools (16 hours course) In this session participants
will learn how to apply a variety of Lean assessment tools to determine
where the greatest savings exist within major manufacturing and
office processes. Tools include: Lean Operations Scorecard; World
Class Metrics Comparison; Industry Comparisons; Problem/Issues identification;
and Opportunity Capture Analysis. The main output will be an identification
of bottom line savings and the determination of a 12 – 24
month set of goals. |
Level Two: Foundational Training > Basic Skills CORE TOPICS SIMply Better Car Company? Lean Manufacturing Simulation (1 day course Minimum/maximum group size is 20-30.) This full-day simulation offers participants the opportunity to experience the principles of Lean manufacturing and actually implement the techniques. The simulation clearly demonstrates how the many aspects of “waste” can be eliminated or greatly reduced to increase product quality, decrease cost, and shorten delivery time.. Participants are given specific jobs or areas of responsibility but are encouraged to change these positions as they become more familiar with “Lean”. The simulation will provide participants an experiences and the working knowledge of Lean, which they will take with them to their place of work. The SIMply Better Lean Office® ( 1 day course) Minimum/maximum group size is 15-20. Requires 2 trainers. This 8 hour hands-on introductory workshop will allow participants to learn and directly apply the principles of Lean enterprise to a typical office environment. Learning applications will quickly demonstrate how to identify and eliminate six types of waste that have significant effect on the bottom-line result of running the office operation. Through 3 progressive applications (from traditional to more progressively Lean) participants will be able to determine profit or loss by actually performing an office process and eliminating waste in the office process to create a Lean process. Lean Manufacturing Techniques (1-day course) The operational techniques that will support a Contemporary Lean organization will be covered, along with specific case studies. Value stream mapping, pull systems, level scheduling, and focus plants will be highlighted. Emphasis will be placed on the interrelationship of each, especially with lead-time reduction, pull systems and visual management. Proper sequencing and timing will be discussed, including when not to implement. 5S - Workplace Organization - (1-day course) Participants will learn the value of 5S to help simplify their work, increase efficiency, improve safety, increase job satisfaction and enhance quality as a part of becoming a Lean organization. Each of the 5S techniques: sort, set in order, shine, standardize and sustain will be introduced with hands on opportunities for implementation. Participants will develop systems to organize the workplace, eliminating unnecessary items and finding a place for the necessary ones. 5S doesn’t stop with the workshop, but becomes a part of the everyday job and a way of thinking. Visual Factory (1-day course) This training session will teach participants how to actually set up visual metrics and signals in their factory. The Visual Factory training approach creates a workplace in which employees have the information they need, understand their role, work more safely, and to contribute in positive ways to company success. These Lean training oriented improvements will improve manufacturing processes and raise productivity levels. Value Stream Mapping Training - (1-day course) Participants will learn how to create a map of the entire value stream. This course teaches how to map the current state of a product or process with the entire current data and non value-added and then map the future state. Participants will learn the steps necessary to eliminate the waste in the system via the power of value stream map in order to achieve the enhanced future state. Participants will bring their own examples and create their own current and ideal state maps. Continuous Improvement
(1-5 day course - tailored) Teamwork in the
Lean Environment (1-day course) Accelerated Lead Time Reduction (1-day course) In this session participants
will look at the current state of a process before implementing
Lean techniques. Participants learn quick and powerful ways to identify
the seven types of operational waste: overwork/overproduction, correction,
movement of materials, processing, inventory, waiting/delay and
motion. Once the waste is discovered participants will map, create
three types of process flow charts and determine how to streamline
the process. Participants learn how to question the way things are
currently being done and apply appropriate Lean techniques to reduce
lead-time. Participants will learn the principles of pull systems and cellular manufacturing and how to effectively implement the techniques into manufacturing operations. They will review the different types of waste and discover new techniques to continue improving the process. Individuals will learn a five-step cell design process and what considerations must be made when evaluating plant layout. They will be able to identify benefits and impacts of redesigning the flow and make good suggestions for improving plant layout. Quick Set Up (1-day course) In this session participants will learn how to reduce time taken to set-up production operations from hours to minutes or even seconds. Participants will learn the disadvantages of large lot sizes and then evaluate current processes using a 5-step system. Examples of operations in various industries that have implemented quick set-up systems are given and then participants begin developing ways to reduce set up time in their workplace. Poka-yoke/Mistake
Proofing (1-day course) Lean Metrics (1-day course) In this session participants will learn how to select goals, projects to achieve the goals, designation of people and resources for project completion, and establishment of project metrics. Examples of Lean metrics and success stories will be used as a support for defining measurements and creating plans. Problem Solving
(1-day course)
Change Management (1 - 5-day course) This interactive training session will be focused on educating and supporting those in the workforce most associated with the areas impacted by changes within the business. The success of any change in business process is directly related to the willingness and readiness to make change by those involved. People need to recognize the basis for their resistance to change, understand that it is natural, and leverage the tools and techniques available for managing change without added stress. Ultimately, people who are ready for change and understand the need for change will embrace and actively participate in making the change succeed. The session will engage participants in structured discussion about change and how to manage the specific changes within the business effectively. PARTICIPANTS: All personnel who will be affected by the planned business process changes. Value Stream Mapping Workshop – Lean Factory (2-day course) This course teaches how to map the current state of a key shop floor process with the entire current data and non value-added and then map the future state. Participants will learn the steps necessary to eliminate the waste in the system via the power of value stream map in order to achieve the enhanced future state. Participants will apply the techniques to their specific office examples and create their own current and ideal state maps as well as develop a plan to implement their ideal state. Value Stream Mapping Workshop – Lean Office (2-day course) This course teaches how to map the current state of an office process with the entire current data and non value-added and then map the future state. Participants will learn the steps necessary to eliminate the waste in the system via the power of value stream map in order to achieve the enhanced future state. Participants will apply the techniques to their specific office examples and create their own current and ideal state maps as well as develop a plan to implement their ideal state. Lean Learn/Do
Kaizen Implementation Workshops (5-day course) Participants will learn by doing when they actually apply the Lean tools to eliminate waste in the work area and achieve breakthrough results that are measurable at the conclusion of the Lean Learn / Do Kaizen Event.
Standard Work (1 - 5-day course) This course teaches the fundamentals of standard work, the practice of aligning Man, Material, Method and Machine to create repeatable, efficient work activities. Standard work is an effective tool to apply when implementing new processes or changing existing processes since it provides a framework and basis for documenting the process in a way that can be utilized and understood by all users. It is also a critical tool in any effort to establish continuous improvement or create consistent performance across shifts or multiple operators. Taichi Ohno, father of the Toyota Production System, said “There can be no improvement without a work standard”. PARTICIPANTS: All personnel who will participate in the redesign or modification of a critical business or manufacturing process. Leading for High Performance in the Lean Environment (8-day course: 16, ½ days) Designed for supervisors, team leaders, superintendents, shop floor engineers quality people, materials people Shop floor performance
metrics need to be linked to and driven by the overall business
objectives. Supervisors and managers need to monitor performance
to insure day-by-day realization of essential metrics:
Coaching for High Performance in the Lean Environment (5-day course <10, ½ days) Designed for managers and executives. This interactive session will be focused on educating and supporting the company’s key managers and executives on the role they need to play to successfully support an effective Lean transformation. The group will meet for one-hour team sessions followed up with 1:1 personal coaching sessions for each participant. Level Four: Thought Leadership Improvement > Advanced Skills Lean Certification Program One (25-day course; 1-3 employees per company) Multiple Companies Program Overview LEAN CERT is designed
to facilitate the development of key individuals in the understanding
and successful hands on application of Lean Enterprise tools and
techniques. It is designed as a multi-step, hands-on, developmental
process, spanning several months. Each pair of Lean Champions work
in concert with their Executive Lean Sponsor to identify and implement
an actual project of great importance in their own workplace. To
become certified, the Lean Champions must clearly demonstrate their
abilities to apply a wide variety of business assessment, planning,
and implementation tools and techniques resulting in a minimum of
$50,000 in realized, bottom line savings. Lean Cert Requirements Lean Certification Program Two: Supply Chain Management Fundamentals (25-day course; 1-3 employees per company) Multiple Companies Program Overview Lean CERT II –
Supply Chain Management (SCM) Fundamentals is intended to connect
the ongoing internal Lean improvement efforts with the companies
supply base and customers. Most companies who have progressed internally
with Lean practices find that suppliers can become the next bottleneck,
whether for quality and delivery issues or a combination of both.
Further, changing customer ordering patterns and shrinking lead-time
requirements place strain on the companies manufacturing operations
and the supply base. Application of SCM tools and techniques can
facilitate a company’s ability to effectively support and
align customer requirements and engage suppliers in solving problems
and ultimately focusing on continuous improvement. Participants
will be exposed to a suite of SCM methodologies through classroom
learning, hands-on activities and implementation of a company based
project that will employ these tools to make an improvement in either
supplier performance, customer service levels or inventory turnover.
Lean Certification Requirements One key Lean/SCM Sponsor
& one - three Lean/SCM Champion certification candidates per
location or company. Lean/SCM Champion participants’ time
requirement is 25 days per person over 6-9 months plus an on-site
SCM project implementation. Each participating company will host
an on-site benchmarking visit, Lean/SCM Overview, and Kaizen/SCM
Improvement event. |
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