Process Optimization and LEAN

Recommended For:
All levels of production managers, engineers, line supervisors, work team members, and production workers.
 
Participants Will:

 
Topics Covered:

 
Details: 4 Hours/.5 Day

Lean 100 is an overview designed specifically for manufacturers. This course will introduce participants to the lean philosophy and the application of basic lean tools. There are 2 rounds of a hands-on manufacturing process simulation. The first round will feature a current-state manufacturing process. The second round near the end of the workshop will allow participants to suggest and implement changes based on the continuous improvement concepts and tools learned during the session.

Recommended For:
Any professional interested in learning more about lean applications. No prior lean training or experience is required.
 
Participants Will:

 
Topics Covered:

 
Details: 14 -16 Hours / 2 Days

Lean 200 encompasses two full days of hands-on learning, and equips participants with practical tools and strategies to make significant and sustainable changes within their organizations. Participants will be led through an interactive simulation of an industry process to allow hands-on application and practice of the Lean tools and methodology.

Recommended for:
Any professional interested in learning more about lean applications within their industry, following the completion of Lean 200: Applying the Fundamentals.
 
Participants Will:

 
Topics Covered:

 
Details: 21-24 Hours / 3 Days

Lean 300 is a 3-day course designed to prepare participants with the information and training needed to facilitate successful kaizen events in an organization. This instruction is for all facilitator knowledge levels. Lean 300 utilizes team breakout sessions, exercises, and other hands-on activities designed to reinforce facilitation. This class is a deep dive into the planning, execution, and follow-up of kaizen rapid improvement events.

Industry Expansion Solutions offers a portfolio of service offerings includes mentoring and advisory programs that provide you with the critical support you need to address both your short- and long-term goals. Our team has decades of experience, across a variety of industries, and we know when and how to give each client the attention they need. At your journey’s successful conclusion, you will have paved the way for continuous improvement, senior leader encouragement management engagement and workforce empowerment to become a way of life at your company.
 
Through a Lean transformation, your company may realize:

 
With Lean, You Can:

Your business is unique, so your Lean transformation should be too. That’s why we customize our solutions, providing overviews, multiple-day instruction 30-60-90+ day programs and numerous scenarios in between. We offer long-term mentoring and follow-up, coaching and further improvement recommendations. We are committed to helping build a sustainable culture change within your organization.
 

Here are some places where we might decide, together, to begin the journey:

 
Five-Day Lean Leader
When you are ready to lead consistent, positive change in your organization, start with the basics: get the fundamentals of continuous improvement methodology and learn the rules and culture of kaizen. You’ll start working with other Lean tools like value stream mapping, as well.
Details: 35-40 Hours / 5 Days
 
Ten-Day Lean Leader
Bring more Lean tools into your toolbox, with the addition of 5S and visual management, standard work and A3 problem solving. We’ll round out the training with a leadership coaching day, to help your improvement program remain sustainable into the future.
Details: 70-80 Hours / 10 Days
 
Fifteen-Day Lean Leader
More coaching! More kaizens! After this intensive training and added practice, you’ll feel confident implementing a whole suite of Lean tools within your organization. With fifteen days of Lean leader training, you’ll also have access to an operations assessment, which identifies your current state and highlights areas of opportunity for additional improvement.
Details: xx Hours / 15 Days
 
Full Transformation
Learn the whole range of Lean tools including mistake-proofing, SMED (changeover reduction), Total Productive Maintenance, Work Cell Development, Pull Production System and Kata problem solving techniques, in addition to the tools listed above. We’ll provide assessments, coaching and support where you need it most.
Details: Ranging 24-30 Days?
 
Full Transformation with Facilitator Support
A dedicated facilitator works with your organization as you move beyond tool kits and recommendations to help you achieve long-term improvement and measurable, bottom-line results. Supportive coaching and facilitation helps strengthen and align leadership, transform processes, optimize management practices and enables you to develop a new
Details: Ranging 24-30+ Days

Recommended for:
Professionals seeking to lead their organizations into the transformative culture of Lean who have successfully completed Lean 200 and 300 course prerequisites and received formal approval by the upper management within their organization.
 
Participants Will:

 
Topics Covered:

 
Details:

You will have up to 24 months to complete your project. Your Lean certificate will be awarded after successful completion of your in house project, assessment of your project by the Lean certificate review board and confirmation of project outcomes by your supervisor or director.

Recommended For:
All levels of business process and office managers, engineers, supervisors, work team members and office workers.
 
Participants Will:

 
Topics Covered:

 
Details: 7-8 Hours / 1 Day

This is a lean basics course designed specifically for business and office processes. This course will introduce participants to the lean philosophy and the application of basic lean tools. Topics include: 8 Wastes, Value-Add versus Non Value-Add, 5S, Standard Work, Value Stream Mapping, and Kaizen. There are 3 rounds of a hands-on process simulation using a Request-for-Quote business process. The objective of the course is to introduce lean concepts then have the participants demonstrate the tools during each round of the simulation.

Recommended For:
Government and non-profit organizations
 
Participants Will:

 
Topics Covered Include:

 
Details:

Lean isn’t just for manufacturing. “Lean thinking” and the tools of Lean manufacturing work in a variety of office, service and industry applications, including government and non-profit agencies.

Lean Government reveals and corrects waste in administrative departments and service delivery processes, so your community enjoys the most value for its dollars. IES has successfully partnered with many local municipalities (small and large) as well as statewide agencies to improve daily work and creatively address common issues using a continuous improvement mindset.

Lean Non-Profit applications help organizations execute rapid cycle improvements to internal processes that have helped increase process efficiency, increase stakeholder involvement and customer satisfaction while decreasing errors, delays and other non-value-added processing steps. Individuals and organizations have made small changes that utilize creativity over capital to brainstorm, test and implement realtime solutions in their places of work.

Lean for the Service Sector applications have helped organizations primarily focused on customer service, sales and transactional functions improve the way they organize for success. Our lean experts have helped by engaging frontline staff and leadership to focus on where the work is done for opportunities to improve operations. Virtual and traditional Gemba walks can help highlight areas where breakdowns in process, communication, and information sharing might occur.

Recommended For:
Hospital, public health, physician practices, home health, community care and community health professionals.
 
Participants Will:

 
Topics Covered Include:

 
Details:

Our lean transformation model will make your patients healthier, your employees happier and your organization more effective. We work with hospitals, public health, physician practices, home health, community care and community health.

We also offer Lean Healthcare Certification to help support medical professionals who desire to help create and lead a culture of continuous improvement throughout their organization.

Recommended For:
Professionals in the human resources field
 
Participants Will:

 
Topics Covered:

 
Details:

The Lean process can assist human resources in identifying value, mapping the value stream, creating flow, establishing pull and seeking perfection.

Lean Six Sigma is a well-structured data-driven methodology that enables organizations to achieve effective and accurate outcomes repeatedly over a period of time.With training and applications ranging from 2 to 18 days,improve manufacturing efficiency and quality, lower costs, enhance cash flow, reduce waste and ensure process stability. These engagements can include: leadership overview; project selection and scoping days, Six Sigma content training, coaching and mentoring days; body of knowledge examination; final project review and Six Sigma certification.

We also offer Six Sigma Yellow, Green and Black Belt training that provides a cost-effective method to train and certify individuals in Six Sigma techniques.

Recommended For:
Any organization in any industry can see positive results with Lean; our clients represent industries including construction, higher education, government and healthcare, in addition to manufacturing
 
Participants Will:

 
Topics Covered:

 
Details:

Lean Sigma 180 takes a unique approach by starting with the improvement project first. Unlike typical Lean Six Sigma training, our team of Lean Six Sigma experts will work with your senior leadership to identify specific improvement projects that are linked directly to your organization’s strategic initiatives— before any training begins.

Those successfully completing our Lean Sigma 180 program will be certified as Lean Six Sigma Green Belts.

Six Sigma is an engineering process that helps companies produce products and services that are almost uniformly perfect; the allowable rate of defects under the rules and principles of Six Sigma is only slightly over three units per million units produced. Six Sigma guides its users in understanding how defects come to be, and subsequently eliminating their root causes. The goal of enacting Six Sigma improvement projects within an organization is to come as close as possible to achieving a defect rate of zero. Six Sigma awards different levels of ‘belts” as practitioners gain experience with the system; ‘black belts” are experts, while “white belts” are just beginning.

The IES Approach Lean Sigma 180 takes a unique approach by allowing green belt candidates to begin with an improvement project before any formal training is given. Our team of Lean Six Sigma experts works with your senior leadership to identify specific improvement projects that directly affect your organization’s strategic initiatives. Projects are not limited to production defects; they might include efficiency or capacity issues, process variation, materials management or maintenance. It is not unusual for these projects to generate savings and efficiencies of $50,000 or even $100,000. The organization benefits from these savings even as the Six Sigma students are training for green belt certification.

Recommended For:
Anyone in an organization who wants to learn Lean Six Sigma principles at a high level —from executive leadership to individually contributing associates
 
Participants Will:

 
Topics Covered:

 
Details: 14-16 Hours / 2 Days

Participants Will:

 
Topics Covered:

 
Details: Ranging from 1-18 Days

Industry Expansion Solutions takes a unique approach to applying Lean and Six Sigma principles simultaneously with education and hands-on learning. Our experts work with you throughout the entire process to educate, train, coach and mentor the future green belt to the successful completion of your organization’s improved process.

We also work with your leadership team to identify specific improvement projects. Not only does your team receive the LSS training, but they gain hands-on practical learnings from their coach and improve a process at your organization. With Lean Six Sigma, benefits materialize quickly and can be sustained long-term.

Topics Covered:

 
Details: Option 1: xx- xx Hours / xx-xx Days Option 2: 4-week course / over 3 month timeframe

Industry Expansion Solutions offers a tailored training program, allowing you to continue your continuous improvement journey in one of two ways:

We offer dedicated project coaching days to assist black belt certification candidates as they progress through their project. Our experts work with you throughout the entire process to educate, train, coach and mentor the future black belt to the successful completion of your organization’s improved process.

Participants Will:

 
Topics Covered:

 
Toyota Kata is a managerial approach which trains people to achieve continual improvement while leveraging scientific thinking. It does not teach problem solving, but rather a mindset that can make people more effective at problem solving. By utilizing this systematic mindset, an improvement culture can be created which will optimize gains made from traditional lean tools. By practicing the Toyota Kata routines and patterns, anyone can become better equipped to navigate ambiguity and reach challenging goals. Kata helps develop the bench strength in your organization through appreciative inquiry and a structured coaching model for kata practitioners and learners.

IES offers a variety of services in Kata including both improvement Kata (IK) and coaching Kata (CK) and their applications. Kata implementation is ideal for companies who may not require a full Lean Transformation but still wish to reap the benefits of core lean tenets including respect for people and a problem-solving culture. Coaching Kata: Guides and teaches the Improvement Kata. Without coaching, a learner may not practice the right pattern, or practice ineffectively. Without coaching, a change in our brain’s wiring is less likely to occur. The Coaching Kata helps develop skills for supporting learners as they practice the Improvement Kata.

Recommended For:
Supervisors, team leaders and anyone who directs the work of others.
 
Implementation Process:
1. Top Management support/participation

2. Select pilot area for initial implementation*

3. Participants develop Job Breakdowns and train employees using Job Instruction

4. Once there is standard work, train participants in Job Methods 10 hour class*

*Customized, alternative training sessions can be accommodated, for example, in greater or less than two-hour sessions (consecutively or non consecutively).
 
Topics Covered:

 
Training Within Industry (TWI) is a dynamic program of hands-on learning and practice, teaching essential skills for supervisors, team leaders and anyone who directs the work of others. It is an essential element of Lean and Continuous Improvement programs around the world including the Toyota Production System. TWI provides a foundation for fostering organizational excellence and transforming business culture.

Industry Expansion Solutions offers three standardized TWI programs addressing the essential skills needed by supervisors, team leaders, and trainers: Job Instruction (JI), Job Relations (JR), and Job Methods (JM).

Learn By Doing—Assures Skills are Applied. After the daily session, trainees return to the workplace to use the techniques learned and choose real-life examples to discuss and practice in class.

Teaches how to quickly train employees to do a job correctly, safely, and conscientiously.

Immediate Results: Provides a methodology for standardization. Skills are taught faster, better, and more consistently from learner to learner.

Long-Term Results: Each time an instructor successfully trains a learner, trust is built. Individuals who trust each other communicate effectively and work as a team. The fear of failure is eliminated because individuals see the positive results and relationships.

Teaches how to build positive employee relations, and increase cooperation and motivation.

Immediate Results: Provides simple strategies for building cooperation. A 4-step approach is taught to handle issues resulting in the best possible outcome.

Long-Term Results: When individuals treat others fairly and with respect, positive relationships are developed through training. Fewer distractions that interfere with performance come from individuals modeling team-like behavior.

Teaches how to improve the way jobs are done.

Immediate Results: Provides a methodology to remove waste from processes for supervisors and operators. Without major disruptions to production, changes are made within their span of control to increase workflow with higher quality and safety.

Long-Term Results: Individuals are more likely to share their ideas for improvement as cohesiveness, trust, and abilities improve within the organization. Collaboration begins to take place and the fear of rejection or embarrassment decreases.

Recommended For:
Anyone responsible for initiating or leading lean, including CEOs, general managers, production managers, controllers, engineers, and materials managers. Suggested follow-up: an in~plant value stream analysis.
 
Participants Will Learn:

 
Topics Covered:

 
Details:

Learn how value stream mapping (VSM) is an effective method used to create a material and information flow map of a product or processes. You begin the journey with the current state map–it shows you where you are. Then, you plan your lean journey with a future state map–it shows you where you’re going and how you’re going to get there. Based on your value stream map, you can streamline your work processes, thereby cutting lead times and reducing excessive operating costs.

Participants Will:

 
Topics Covered:

 
Details: 14-16 Hours / 2 Days

Hoshin Kanri—A Strategic Approach to Continuous Improvement
The HK methodology employs a structured planning and deployment cycle during which goals are determined, plans to achieve the goals are established and measurements are created to ensure progress toward these goals. It ensures these goals drive progress and action at every level within the organization by eliminating the waste that originates from inconsistent direction and poor communication. HK strives to get every employee pulling in the same direction, at the same time. It achieves this by aligning the goals of the company with the plans of middle management and the work performed by all employees.

The initial steps of Hoshin Kanri planning are similar to other strategic planning processes. Management teams gather data on current performance and identify current and future customers and their needs. A SWOT analysis is conducted, assessing four important aspects of the business. The mission and vision is refined, ensuring KPIs are still relevant.

Hoshin Kanri then departs from other standard planning processes in multiple ways: the degree of focus, the involvement of all levels of the organization, the use of planning and process improvement tools and the rigor of the reviews. HK recognizes and values the concept of true north as well as the importance of the communication and transparency of the direction.

Participants Will:

 
Topics Covered:

 
Details: 7-8 Hours / 1 Day

Managing for Daily Improvement (MDI) is a process in which an organization implements visual management strategies and facilitates key performance indicators (KPIs) at the ground level with day-to-day employee activities. MDI flips a top down management approach to drive change from the bottom up.

MDI makes problems visual and explicit (if a problem is not seen, it can’t be solved) and engages the entire team around solving problems. It allows for rapid and frequent course corrections and creates a daily habit of performance management.

Recommended For:
Anyone responsible for initiating or leading a lean initiative including CEOs, general managers, plant managers, lean facilitators, engineers and materials managers. Anyone with a desire to improve a work area or office area with continuous improvement tools of standardization including office managers, supervisors, lead operators, industrial/manufacturing engineers and quality managers.
Participants Will:

 
Topics Covered:

 
Details: 7-8 Hours / 1 Day

This program will teach the foundation necessary to achieve success in continuous improvement programs by preparing the manufacturing process with repeatable standard systems.

Total Productive Maintenance (TPM) is a process that maximizes the productivity of equipment for its entire life cycle to extend the life of the equipment. Through the participation of both operational and maintenance associates, TPM creates an environment that encourages improvement efforts in safety, quality, cost, delivery and creativity. Our program focuses on eight pillars: autonomous maintenance; planned maintenance; early equipment management; quality, health and safety; focused improvement training and education; and TPM in the office. Participants will receive a combination of classroom training paired with real time instruction and application with an IES expert on the shop floor.

Quick Changeover (SMED): Wasteful, non-value added activity takes place both during machine runtime (external activities) and while the process is shut down (internal activities). SMED workshops focus on reducing and eliminating this waste and increasing capacity, time availability and resource availability in the process. Changeovers consist of the time between the last good piece off the current run and the first good piece off the next run, at rate.

SMED (Single Minute Exchange of Dies), or Changeover Reduction, focuses on reducing the time and impact of key elements in the changeover process including preparation; after-process adjustment; checking, storing, and moving materials, parts and tools; removing and mounting parts and tools; machine measurements, settings and calibrations; trial runs and adjustments.