MasterClass Series
Table of Contents
Fixing the Basics: Preparing for the Lean Journey
Outline
Before starting any programme of business change, we must ensure that our foundations are solid. In our experience, too many companies dive into initiatives with little or no preparation, assuming that business processes exist and that they are being complied with.
This MasterClass will help you get ready for your lean implementation. It will identify the key areas that need to be well established for the lean implementation to ‘take’.
Content
- Understanding the basics – the 5 Ps
- Assessing readiness and operational maturity
- Steps we can take to stabilise
- Starting points – how we establish control
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
- Six Sigma Specialists
Duration: 1 day
No. of Participants: 6-10 people
Lean Performance Management
Outline
Measurement of performance is an integral part of any lean implementation. We need to understand current levels, we need to understand the future state and we need these measures to be simple, real time and appropriate to the user group.
Recognising performance from the customers standpoint, this MasterClass will introduce you to the metrics used in a lean implementation and will help define the most appropriate way of implementing and cascading throughout the organisation, at every level.
Content
- Why measure?
- Who should measure? Which Organisational levels? Which roles?
- What should we measure? Examples:
- Quality – scrap, rework,
- Cost – WIP, Stock, Productivity
- Delivery – On time, in full (OTIF), Lead time
- Where should we measure performance?
- Understand the gates in your value streams and the appropriate measures for each
- How should we measure? Control boards, business plan deployment or local area controls
- When should we measure? Frequency of data collection, analysis review and reporting
- Introduction to example measurement styles and formats
- Personal Action Planning and Implementation route maps for your business
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
- Six Sigma Specialists
Duration: 1 Day
No. of Participants: 6-10 people
Lean Business Diagnosis
Outline
There can often be confusion around the journey to becoming lean or becoming world class; where are we in relation to world class businesses? What steps do we need to take to progress? How do we know if we are getting better?
There can often be confusion around the journey to becoming lean or becoming world class; where are we in relation to world class businesses? What steps do we need to take to progress? How do we know if we are getting better?
Our diagnostic is designed to be easy to use, easy to understand and is focused on improving processes to gain results.
This 1-day workshop will introduce you to the diagnostic tool and how it supports the development and improvement of your business processes.
Content
- Overview of the tool: its roots, design, and use
- How to use the tool – practical examples of application and development points drawn from previous analysis
- Self assessment and the scoring mechanism; levelling up and gaining consensus
- Interpreting the results; prioritising actions and development of the improvement roadmap
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
- Six Sigma Specialists
- Supplier Devlopment staff
Duration: 1 Day
No. of Participants: 6-10 people
Value Stream Mapping
Outline
Value Stream Mapping is a powerful tool that allows us to gain a better understanding of our processes and the factors that influence value creation and identifies areas that can be targeted for improvement action.
This 2-day workshop will introduce you to the methodology and thesymbols and templates used to create a Value Stream Map (VSM) and will use practical examples to put these into practice.
Content
- Roots and development of VSM in the lean community
- How to prepare and get ready for your VSM study
- Process selection and methodology
- Introduction to the symbols and VSM construction
- Worked example comparison
- ‘Current state mapping’ – practical exercise and improvement discussion
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
- Six Sigma Black Belts
- Improvement Managers
Duration: 2 Days
No. of Participants: 6-10 people
M3 Kaizen
Outline
Engaging your workforce in improvement activities can often generate good feeling but no real results. This can be caused by a lack of improvement process, a lack of improvement skills or, most commonly, a lack of focus and activity selection.
Our M3 Kaizen Process helps address these failings and will energise your teams to focus on the three key loss areas that manifest themselves in all types of business:
- Muda – Waste
- Mura – Variability/Irregularity
- Muri – Difficulty/Strain
and uses the Plan-Do-Check-Action approach in these areas to eliminate or reduce Waste, Variability and Difficulty.
This workshop will introduce you to the planning processes for improvement activities, identifying improvement areas and how to select the right tools and techniques to make a sustainable improvement.
Content
- The M3 Process and the PDCA cycle of improvement planning and execution
- The three Ms; what they are, how we can identify and quantify their impact and practical examples from business
- Planning and executing a Kaizen activity or event
- Types of Kaizen activity: SMED, Workplace Organisation, Productivity improvement etc.
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
- Six Sigma Black Belts
Duration: 1 Day
No. of Participants: 6-10 people
Industrial Engineering Tools for Kaizen
Outline
Often the forgotten gold mine of improvement, Industrial Engineering (IE) has suffered in recent years from some bad press and lack of strategic direction. Today the IE resource is seen as much more than ‘time and motion analysts’ and rate fixers.
The suite of tools and skills that a good Industrial Engineer brings to your business is invaluable in support of both your business plan deployment and improvement programme execution.
This ½ day workshop will introduce you to the role of the IE and the tools and methodologies that an IE can engage in support of your goals.
Content
- The previous role of the IE and mistakes to avoid; the history, the application and goals
- The modern IE; how to find them, how to train them and what they can deliver
- The tools and techniques available to the business:
- Factory Design and Layout
- Creating flow in processes
- Ergonomics and workplace design
- Work Measurement techniques
- Method analysis and improvement
- Costing systems and Standards support
- Manpower planning
- Capacity analysis and bottleneck identification
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
- Industrial Engineering
- Manufacturing Engineers
Duration: 1 Day
No. of Participants: 8-15 people
Quick Changeover – SMED
Outline
In today’s fast moving, Just in Time environment, the ability to changeover machines and processes quickly is paramount.
This class will give an understanding of why Changeover Reduction is necessary from both the Stock Reduction and Total Productive Maintenance standpoints.
It is designed to be practical in nature and will allow the candidates to apply the necessary tools and techniques in a working environment by using one of our realistic simulations.
Content
- The need for Quick Changeover.
- Where it fits in to a Stock Reduction and/or T.P.M. programme
- The five steps for changeover improvement
- Practical exercises employing the techniques for set-up reduction
Who will benefit?
- Maintenance Engineers
- Manufacturing Managers
- Team-leaders
- Supervisors
- Machine setters
- Production
- Materials
- Engineers
- Purchasing Development staff
- Supplier Development staff
Duration: 1 Day
No. of Participants: 6-12 people
5S – Workplace Organisation
Outline
The key to any form of improvement initiative, whether founded on TPM, Lean, Six Sigma etc. is an organised workplace.
This MasterClass will address the myth that 5S is only a ‘keep things tidy and clean’ initiative and will explore the real depth to a successful programme; what 5S is really about, what it covers and the deeper applications.
Content
- 5S Origins and philosophy
- Where it fits with other business improvement programmes
- Applications – Manufacturing, Services and Office programmes
- Roles and Responsibilities within the programme
- Measuring success and sustaining the improvements
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Team-leaders
- Supervisors
- Machine setters
- Production
- Materials
- Purchasing Development staff
- Supplier Development staff
Duration: 1 Day
No. of Participants: 10-15 people
Kanban Overview
Outline
Supporting the flow of materials through the value stream, kanban is a control system that ensures that minimum inventory is held and that work sequence is preserved. Kanban means a visible record and is a trigger mechanism to make or move material on a ‘pull’ basis.
This system can often replace conventional shop floor control methods and can be used to link internal production processes as well as external suppliers within the supply chain.
This workshop will provide a guide to establishing and operating kanban systems within the manufacturing environment. It covers internal kanbans, between manufacturing or business processes and external supplier customer kanbans.
Content
- Definition and types of kanban
- Principles of operation
- Selecting which parts to kanban
- Setting size and number of kanbans
- Selecting containers and storage layouts
- Supplier kanban agreement
- Operating kanbans
Who will benefit?
- Logistics Management staff
- Materials Management staff
- Purchasing Managers
- Operations staff
- Lean teams
Duration: 1 Day
No. of Participants: 6-12 people
Standardised Working Overview
Outline
Standardised Working is the back bone of “World Class” manufacturing, standing as the very best way of doing a particular task at any one point in time. This module is variable from a one-day overview to a ten day, intensive, on-site training and activity programme and is applicable to all managers, supervisors and shop floor personnel.
Participants will understand through simulations and exercises, what Standardised Working covers, how to establish the standardised process and how to assure the quality. They will then plan how to introduce Standardised Working Procedures to their own areas.
Content
- What do we mean by Standardised Working?
- Integration with business systems: costing systems, capacity and manpower planning
- Applications – Manufacturing, Services and Office programmes
- Roles and Responsibilities within the programme
- Measuring success and sustaining the improvements
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
- Industrial Engineers
- Manufacturing Engineers
Duration: 1 Day
No. of Participants: 8-15 people
Introduction to Total Productive Maintenance
Outline
Often the forgotten gold mine of improvement, Industrial Engineering (IE) has suffered in recent years from some bad press and lack of strategic direction. Today the IE resource is seen as much more than ‘time and motion analysts’ and rate fixers.
The suite of tools and skills that a good Industrial Engineer brings to your business is invaluable in support of both your business plan deployment and improvement programme execution.
This ½ day workshop will introduce you to the role of the IE and the tools and methodologies that an IE can engage in support of your goals.
Content
- Total Productive Maintenance – roots and history
- The 12 step process for implementation
- Benchmarking for TPM
- TPM and Autonomous Maintenance
- TPM Performance Measures:
- Overall Equipment Effectiveness (OEE)
- Mean Time To Rectify (MTTR)
- Mean Time Before Failure (MTBF)
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
- Maintenance Managers
Duration: 1 Day
No. of Participants: 10-15 people
Quality Tools Overview
Outline
The range of problem-solving techniques in existence is vast and as such specific industries and specific client needs usually dictate which particular techniques are most appropriate. Consequently, this module can be tailored to suit and has taken the form of a one-day ‘general’ workshop, to a ten-day on-site activity. The common theme throughout however, is to categorise problem solving techniques into those that “filter”, those that “overcome” and those that “control”. This module is therefore appropriate for any level of participant.
The workshop also introduces a framework for the deployment of the tools and forms the basis of a Concern and Corrective action reporting system.
Content
- The PDCA and DMAIC approaches to problem resolution
- Introduction to the quality tools
- Problem definition
- Selection of the appropriate tools and methodology
- Application of the tools
- Expected outputs
- Forms of Root Cause Analysis
- Teams in problem solving
- Concern and Corrective Action Reporting
Who will benefit?
- Manufacturing Directors
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
Duration: 1 Day
No. of Participants: 10-15 people
Autonomous Maintenance – Initial Activity
Outline
This is a host company practical workshop and is designed to give the attendee a first level awareness of Autonomous Maintenance activities that form the backbone of a successful Total Productive Maintenance programme.
It will provide the attendee with an overview of TPM, but will focus on the first three steps of a seven step programme in the implementation of full Autonomous Maintenance. Based on the shop floor, this workshop has been created to introduce all levels of the organisation to the process of improving equipment.
Content
- Total Productive Maintenance overview
- The seven step approach to Autonomous Maintenance (AM)
- What is it?
- What does it involve?
- Conduct team based Clean and Check activity on equipment
- Creating Daily/Weekly Check sheets for Lubrication and Cleanliness
- Develop Housekeeping Standards for area
Who will benefit?
- Maintenance Managers
- Manufacturing Managers
- Production Managers
- Supervisors
- Lean teams
- Business Improvement staff
- Supplier Development staff
Duration: 2 Days
No. of Participants: 6-12 people
Presenting With Confidence
Outline
For many of us, presentations are unnatural and therefore sources of great discomfort. However, in today’s world, preparing and giving presentations is no longer the domain of the sales function and the need to give effective presentations to colleagues, bosses, suppliers and even the public can apply to all of us.
It needn’t be a torturous experience though. You don’t actually need to suffer stress and weightloss in the run up. Presenting can be enjoyable and an opportunity for you to put yourself on show.
This MasterClass will help you get ready for your presentation and will provide you with a system to ensure that you can deliver it with confidence.
Content
- Preparing for your presentation
- Designing the style and content
- Delivery of your presentation – the four key steps
- Evaluation of your performance and audience feedback
Who will benefit?
- Interview Candidates
- Buyers
- Sellers
- Managers
- Process Owners
- Business Improvement staff
Duration: 1 Day
No. of Participants: 6-10 people
Negotiate the Deals You Want
Outline
Richard M. Nixon once said that, “After an era of confrontation, the time has come for an era of negotiation.” In today’s business environment, where Customer/Supplier relationships are being based on Partnership rather than the traditional adversarial approach, Nixon’s words hold true.
Unfortunately, there is a false belief that good negotiators are born and not made and very little attention is paid by today’s organisations to this difficult interpersonal skill.
This workshop will provide attendees with an understanding of various negotiating techniques, how to plan for a negotiation and how to successfully conduct the process of negotiation. With practical examples of how negotiations work, backed up by practical role playing exercises, this workshop will ensure that the participants return to their own environments with the capability and attitude to negotiate successfully.
Content
- Introducing the five step process in preparing and delivering your negotiation plan
- Identifying your goals, objectives and supporting information
- Designing your negotiation strategy and plan
- Delivering your negotiation: negotiation style, bidding and bargaining and trading
- Assessing progress and achievement
- Evaluation of process and results
- Practical exercises and role playing
Who will benefit?
- Anyone involved in the negotiation process
- Anyone who attends negotiations in a supporting role
Duration: 1 Day
No. of Participants: 6-10 people
Making Sense of Accounts
Outline
Knowing your way around a P+L and a Balance Sheet used to be the responsibility of the financial controller or company secretary.
However more and more people are finding that knowledge of accounts, what they mean and how they link up, is important in everyday life too. Buyers, sellers, business owners, club secretaries and charity organisers all require a basic understanding.
This workshop is designed for the numerically nervous and is delivered at at a level to ensure understanding.
Content
- The components of finance
- The Profit and Loss account
- The Balance sheet
- Cash Management
- Ratios and financial performance
Who will benefit?
- Non-financially qualified personnel
- Personnel involved with numbers and accounts
- Personnel who require a brush up on some rusty skills
Duration: 1 Day
No. of Participants: 6-10 people