Basic Lean Methods:
2 consecutive days
- Introduction to Lean Enterprise
- Current State Map / Value Stream Mapping
- Waste (8 types of waste)
- Visual Controls / The Visual Workplace
- Principles of Lean (Process, Flow, Pull)
- Future State Mapping
- Key Factors for Success
Course can also be offered in a Kaizen event format to address and resolve a critical business issue in a fast and effective manner.
Lean Improvement / Kaizen Events:
Sample Results from 3 - 5 day Lean / Kaizen Improvement Events:
- Contract Manufacturer: Assembly labor costs lowered by 40% and WIP reduced by factor of 100+ ($1M annual savings)
- Reduced the cycle time of a high volume Apparel Marking and Grading process by 40%.
- Improved a Sales Management process, saving $210.6K annually through lowering loss due to better exception reporting and SKU error reduction.
- Sales Order Process reduced paperwork by 43% and increased ability to respond to upside business by 15% ($750K/yr.)
- Medical Device manufacturer cut 50% of a manufacturing stage cycle time resulting in $250K inventory reduction as well as reduced process costs by 40% on a single product line.
- Aerospace/Automotive OEM reduced RFQ cycle time by nearly 50%
Lean Sigma (Greenbelt) Training:
5 days (Instruction and project time)
- Intro to Six Sigma & Lean
- DMAIC Modules
- Define (Project Selection, Kano, VOC, SIPOC, RTY, CTQ)
- Measure (Process Analysis, Basic Statistics & SPC, Collecting & Summarizing Data)
- Analyze (Exploratory Data Analysis, Basic Descriptive Statistics)
- Improve (Basic DOE Concepts, Lean Improvement Concepts)
- Control (Process Control Planning)
- Instructional Design supported by the Quality Council of Indiana
Course can be offered in a multi-week format to accommodate project work
between sessions. |
