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Manufacturing Business Specific Services 5S Train the Trainer with Example Area Kaizen 5S Train the Trainer with Example Area Kaizen How can such a simple concept such as “workplace organization” improve safety, increase throughput, reduce errors, open up space, and make your organization more visual? The practice of “5S — Sort-Set-Shine-Standardize-Sustain” is a foundational building block to lean. Beyond the already mentioned benefits, 5S deployment teaches your people team work and begins to build a process focused culture. This two to four day event provides detailed training not only on what 5S is and how it functions, but on how to deploy it within your specific organization’s manufacturing area. As part of the training the team actually uses the 5S tool set to optimize a predetermined area within your facility. This area will serve as an example/model area to reference for future expanded deployment. Participating team members participating in this event will be qualified to be trainers for 5S throughout your organization. Objectives:
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Standardized Work Training and Kaizen Event Standard Work is the manufacturing method that is required to make product in a safe, defect-free, cost effective manner. Without standard work there can be no improvement. In order to improvement you must understand your starting point. This training/event teaches the lean tool of standardized work and applies it to one manufacturing process. The course requires minimum prep work of approximately 2 to 4 hours in selecting the process to standardize. The course last approximately two to three days based on the complexity of the process. These days can be done consecutively or broken into single days across weeks to reduce the strain upon your organization. Objectives:
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Continuous Flow and Pull Training/Demonstration/Kaizen Event I would like to invite you on a journey where we learn by playing – Flow where you can, Pull where you can not. This four day event reviews what continuous flow is, how it can benefit you, and demonstrates how pull systems can be implemented to benefit the business when flow is not achievable. It begins with a Lego Block demonstration exercise and ends with an actual onsite kaizen event to implement Pull within a pre-determined area of your site. Objectives:
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Setup Reduction Training and Kaizen Event Setup reduction will improve your equipment availability, increasing the total capacity of your equipment. This means better utilization of operator’s time and capital investment reducing your overall need for future capital investment. More importantly, reduced setup time makes smaller batch sizes possible, without the economic penalty, the result – a reduction of overall lead times, reduced inventory and storage space needs and reduced scrap and rework rates. This is a two day course with a combination of classroom activity and hands on application. Objectives:
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Error Proofing is a systematic approach for anticipating and detecting potential defects and preventing them from reaching the next process step or the end customer. Real world examples of error proofing are: Unleaded fuel tank filler openings on fuel tanks; spell check in word processor software; and sink overflow outlets. This one day, 4 hour course shows you how to apply similar techniques within your manufacturing environment. Objectives:
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Total Productive Maintenance Training and Program Deployment In many companies, a new machine asset begins to sink into a downward spiral of more and more downtime starting with the first day that the new machine is used for production. Total Productive Maintenance (TPM) is a continuous multiple step process that ensures that everything possible is done to keep your equipment making good quality parts, at your desired production rate, every time wanted. This event is a combination of training and the hands on activity of applying TPM to a single machine within your facility. There is approximately 30 days of pre-work monitoring of the chosen machine prior to the official event startup. This 30 day period will be kicked off with training on what to monitor and how. Once the data is obtained another day will be spent evaluating what we have observed. More planning takes place, after which we begin the event. The event last approximately five days. Objectives:
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If you are expanding or reducing your operations, I have years of experience developing systematic layout plans that make use of Lean Manufacturing techniques for all types of operational areas, including manufacturing, stockroom, distribution and support activities. These layouts incorporate improved flow of materials, proper storage and staging, and improved material handling systems in order to improve your business and meet resource constraints. Please contact me directly to review your project scope.
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