Lean Program with Pilot Implementation

Program Objectives

• Training a team to understand and implement a Lean production system
• Implementation of theoretical knowledge acquired in two pilot areas
• Lean responsible mentoring

Delivery

• The program will run over a period of several months in two pilot areas, with the support of a team of the beneficiary, personnel from the pilot area: production, maintenance, engineering, quality (optional: logistics, sales, HR). This team will participate in all training/coaching sessions and putting activities into practice.
• The consultant will support the implementation through several theory and coaching modules for the transformation of the pilot areas.
• Between the training modules, the designated team will have to implement in the pilot areas the tasks received after completing each theory module.
• At the beginning of each module, the Consultant will audit the implementation of the tasks in the pilot areas and support the team in improving their application.

At the end of the program, a theoretical test will be given, the completion of which, together with a Power Point documentation of the implemented actions, will constitute the basis for the issuance of Lean Green Belt certificates for each participant, team member.

The program can be extended/modified depending on the needs identified during the project and based on the agreement with the Client.

Program propus

Module	Duratio	Main Topics	Implementation
M1: Introduction to Lean; Objectives Management (KPI).	2 days	Principle presentation of the Lean concept, the notions of Added Value vs. Waste;	Establishing and communicating performance indicators for processes, starting with the management level and descending to the team / individual level
M2: Teamwork; 5S & standardization.	2 days	What is a team, communication concepts, qualification matrix; 5S, 5S audit, cycle and tact time, process balancing	Qualification matrix, 5S, 5S audit, Work instructions
M3: Visual Management; Continuous Improvement; Equipment Management; Quick Adjustments (SMED)	2 days	Visual Management, Suggestion System, what is Equipment Efficiency (OEE), calculation and application; introduction to TPM; What is SMED and how to apply it to reduce setup times	Process flow charts, Dashboards, Visual Management elements in production, Calculation, data collection and layered OEE reporting; SMED Workshop
M4: Problem solving techniques.	2 days	5 Whys, Ishikawa, Brainstorming, time diagram, Pareto	Systematic approach to solving problems (related to efficiency)
M5: Notions of preventive and autonomous maintenance. Current situation assessment.	2 days	Introduction to the concept of preventive and autonomous maintenance. Auditing the implementation status of actions & feedback	Preventive and autonomous maintenance procedures
M6: Process Analysis. Current status assessment and expansion planning	2 days	Presentation of tools - includes Flow Chart, Value Stream Map and their chaining. Assessment of current status of implementation of measures in pilot areas. Review. Management/team workshop for future measures.	Support in implementation of backlogs. Value Stream Map

Optional additional modules: Introduction to Lean for Management, Norms, Workplace Ergonomics

Depending on the initial clarification discussions and the evolution of the program, the number of days can be changed (decrease/increase) by mutual agreement.

Consultants

The program will involve 1-2 consultants, with over 20 years of experience in the lean environment, automotive, heavy industry, furniture, electronics and consumer goods, including implementations from scratch.

The consultants have management experience in various departments: engineering, quality, production or company management and in this way have acquired very good communication, change management and coaching skills.

Other clients in our consulting and training portfolio:

Albalact, Scandia Food, VPK Packaging Romania, FrieslandCampina, Daimler,Coficab, Continental, Delphi, Draexlmaier, Pgs Sofa & Co Srl, Leoni Wiring Systems, Astra Rail, Hella, Arctic, Robert Bosch, Takata, Compa Bilstein, Preh, Autoliv, Fujikura, BOS Automotive Products, Kromberg & Schubert Romania, Federal Mogul, Eaton Electric SRL, Rombat, Ecolor, EKR Electrokontakt, Harting, Grupo Antolin, Eckerle Automotive, Benchmark, Trevertex, BOA Group, Voestalpine and others.