The Essential Lean Toolbox Training Course

The Essential Lean Toolbox Course has been designed by industry leading Lean Consultants for individuals wishing to transform their workplace into one driven by continuous improvement. In just 5 days you will have the knowledge to drive waste from your business and implement a sustainable Lean Manufacturing programme.

Personnel with responsibility for improving business performance and sustaining profitable growth should attend:

• Owner Managers
• Managing Directors
• Operations Directors/Managers
• Production Managers/Supervisors
• Senior Shop Floor Personnel
• First Line Managers
• Team Leaders

We would recommend you attend all 5 days but would also allow you to ‘Cherry Pick’ should you feel this is more relevant to your business. Each module will have individual certification and an Essential Lean Toolbox Program Certificate will be awarded to attendees of all modules.

Personal Development

To encourage personal development attendees are provided with research documentation at the end of each session, which should be completed before the following module (not compulsory). It is advised that attendees request a mentor from their employer (Futurestate Solutions mentoring can be provided on request) as this encourages teamwork and leads to a sustainable business culture. This also ensures that the learning has been understood and that you are prepared to go out there and ‘DO IT’.

Course Tutors

Consultants and Trainers within Futurestate Solutions Ltd have proven business experience in a Lean Manufacturing environment and receive excellent feedback on course delivery. We are passionate about achieving results from our courses but also understand that sitting through hours of theory can be a little boring. Therefore we all maintain a sense of humour, discuss relevant issues and utilise as much practical work as possible.

Day 1

1. Lean Awareness

Objectives

• Gain an understanding of the size of the opportunity for business improvement that lean operations represent
• Provide an understanding of the principles of lean manufacturing
• Understanding of types of waste within your business and how removal can lead to improved factory layout
• Develop skills to apply waste elimination techniques and learn how to apply to ALL business processes

2. Workplace Organisation (5S)

Objectives

• Understand the importance of workplace organisation and how 5S can improve performance
• Learn how to develop Standardised Work
• Introduction of Auditing to control workplace organisation
• Understand how visual management can lead to effective performance

Day 2

3. Value Stream Identification

Objectives

• Understand the importance of identifying the ‘Value Streams’ in your business and how customers drive the processes
• Learn the different types of 'Value Streams' and how they drive processes
• Identify true customer value and what this means to your business

4. Value Stream Mapping

Objectives

• Learn how to map your current and future state using Value Stream Mapping tools
• Uderstand how cross functional teams can improve overall business performance
• Learn how to create an effective Action Plan to drive the improvement process

Day 3

5. Total Preventative Maintenance (TPM)

Objectives

• Realise the importance of reducing ‘downtime’ and how it affects flow
• Learn to identify maintenance problems before they cost you money
• Understand the need to introduce a planned maintenance schedule as a foundation for business improvement
• Learn how to measure Overall Equipment Effectiveness (OEE) and develop a programme to improve performance

6. Single Minute Exchange of Die (SMED)

Objectives

• Understand the need for quick changeovers and how this can improve flow
• Learn how to apply SMED techniques and reduce changeover times
• Understand the importance of quick changeovers in a lean environment

Day 4

7. Site Visit to Lean Company

Objectives

• Site visit to ‘Lean Company’ to experience an environment that has implemented the majority of Lean Manufacturing Techniques available but is still in the teething stage
• Tour of Factory to see first hand the opportunties for your own business
• Opportunity to discuss learning and how it can be applied

8. Quality Tools and Problem Solving

Objectives

• Understand the tools and techniques of a team focused quality management system
• Understand the need to measure and collect data with problem solving techniques
• Analyse ‘The 7 Quality Tools’ and incorporate a worked example for each tool to improve understanding of the tool and its application
• Understand the concept of Statistical Process Control (SPC)

Day 5

9. Policy Deployment

Objectives

• Understand the importance of setting company objectives and its relationship with a continuous improvement culture
• Learn how to develop a business strategy based on overall vision
• Best methods of deployment and involving the whole team
• Measurement considerations when outlining growth plan

10. Lean Manufacturing Implementation Considerations

Objectives

• Identify key areas of learning over past modules
• Discussion on pitfalls and how to sustain your improvement programme
• Question and Answers session on Lean Tools and Techniques
• Opportunity to arrange site visit to own business