Lean Program with Pilot Implementation
Category: 05_LEANLength: 12 days
Planning:
Objectives of the Program
- Training a team to understand and implement a Lean production system
- Implementation of the theoretical knowledge acquired in two pilot areas
- Responsible Lean Mentoring
Agenda
- The program will run for 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 implementation of the activities.
- 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 will support the team in improving their application
At the end of the program, a theoretical test will be given, the graduation of which, together with a Power Point documentation of the implemented actions, will form 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
|
Module |
Duration |
Main topics |
Implementation |
|
M1: Introduction to Lean; Goal Management (KPI). |
2 days |
Process analysis. Current status assessment and expansion planning |
Establishing and communicating performance indicators for processes, starting with the management level and going down to the team/individual level |
|
M2: Teamwork; 5S & Standardization. |
2 days |
What is the team, notions of communication, 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 Settings (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 in order to reduce set-up times |
Process flow charts, Panels with indicators, Visual Management elements in production, Calculation, data collection and OEE stratified reporting; SMED Workshop |
|
M4: Problem-solving techniques. |
2 days |
5 Why, Ishikawa, Brainstorming, Time Diagram, Pareto |
Systematic approach in solving problems (related to efficiency) |
|
M5: Notions of preventive and autonomous maintenance. Assessment of the current situation. |
2 days |
Introduction to the concept of preventive and autonomous maintenance. Audit of the implementation status of actions & feedback |
Preventive and autonomous maintenance procedures |
|
M6: Process analysis. Current status assessment and expansion planning
|
2 days |
The presentation of the tools includes the Flowchart, Value Stream Map and their chaining. Evaluation of the current state of implementation of measures in pilot areas. Examination. Management/team workshop for future measures.
|
Preventive and autonomous maintenance procedures |
Optional additional modules: Introduction to Lean for Management, Standardization, Ergonomics of the workplace
Consultants
The program will involve 1-2 consultants, with experience in the lean environment for over 20 years, automotive industry, heavy industry, furniture, electronics and consumer goods, including implementations from scratch.
The consultants have leadership experience in various departments: engineering, quality, production or company management and in this way they 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 și alții.
Offer is valid for 30 days from the date of issuance
