Resources

• Lean, On Me

  Print this Free Resource to help step you through the 10 Key Concepts that make up your Journey to Lean Thinking.

• Project Benefit Toolkit

  Examples of Savings / Benefit categories and sample calculations.

• 5S Guides

  These guidelines are designed to be used as a roadmap to prepare for and perform 5S activities. These tutorials are based on lessons learned and the experience of early pilots. The are not all-inclusive. They can be changed to fit your application and are a great resource for Lean coordinators.

Foundations

• TPS Overview (Dr. Woll)

  The key to the Toyota Way and what makes Toyota stand out is not any of the individual elements.... but- what is important is having all the elements together as an operating system.

• How to Become Lean

  Interested in adopting Lean Thinking for your organization? This module lists, step-by-step, the actions you should take to begin the journey.

• Lean Enterprise Philosophy and Concepts

  This material answers the basic question: What is a lean enterprise and what are it's various elements? The four goals of Lean Thinking, the 7 categories of Muda (waste) and several other Lean principles for creating value and eliminating waste will be explored.

• Why Change?

  This material answers the question: Why pursue continuous improvement? Learn the characteristics of an organization in need of change and become familiar with some basic building blocks of Lean and its' 4 main goals.

• Root Cause and Corrective Action

  Commonly called RCCA, this technique is a process for finding the true cause(s) of events; identifying and implementing corrective actions; assessing the effectiveness of those actions and preventing recurrence of the event(s). Utilizing the "5 why" technique and others, participants will dissect the direct, contributing and root causes of a problem and learn the two types of corrective action. Corrective Action Matrix (Form) included.

• Vital Links: Lean, Six Sigma and Change Management

  Explore the component parts of a Continuous Improvement Process (CIP) and how Six Sigma, Change Management and Lean methodologies work together within the D-M-A-I-C problem-solving process.

• Value Stream Mapping (VSM)

  Steps for documenting and mapping a process are presented. Examples of process mapping and value stream mapping are also provided. Basic VSM symbols included.

• Value Stream Mapping Symbols (VSM)

  Basic VSM symbols included in a Power point format.

• Value Analysis /Flow Analysis

  Participants put on their cost reduction hat, as they learn that the value of the output can increase by either reducing costs or increasing effectiveness. Simple critical thought and questioning techniques, applicable to any process needing improvement, are provided.

• Without the Cost of Waste

  Simple waste elimination tips applicable to any process.

• 5S

  5S provides a basis for being a world-class competitor and the foundation for a disciplined approach to the workplace. 5S is the springboard for Lean Thinking. The purpose of this module is to introduce the 5S philosophy, actions, and measurements. A step-by-step process is provided for implementing each 5S activity. A case study showcases "before and after" pictures. Spider chart form tracks implementation progress.

• 5S Area Rating Form
  (Spider web)

  5S provides a basis for being a world-class competitor and the foundation for a disciplined approach to the workplace. 5S is the springboard for Lean Thinking. The purpose of this module is to provide simple checklist and scoring form in relation to the 5S methodology. Evaluations (audits) should be performed monthly.

• 5S in the Office (video)
  

  Case study from Kyocera, San Diego, CA.

• Executive 5S

  This presentation introduces the benefits of 5S and showcases several industry examples. Use this presentation to promote 5S with your leadership team or to up-sell 5S with a "sister division" within the same company.

• 5S Area Rating Exercise

  5S provides a basis for being a world-class competitor and the foundation for a disciplined approach to the workplace. 5S is the springboard for Lean Thinking. The purpose of this module is to practice evaluating area conditions in relation to the 5S methodology. Evaluations (audits) should be performed monthly.

• TPM

  Total Productive Maintenance (TPM) begins with the premise that Goals are set for Machine performance - commonly called "OEE" (Operational Equipment Effectiveness). Loss of equipment efficiency falls into five categories, data is collected, and priorities set for those areas. After learning these concepts, Teams develop a TPM plan and attack the six big losses due to poor maintenance; learn the seven elements of Autonomous Maintenance and categorize the machine problems into availability, performance efficiency, and quality. Posting visual displays of Performance Metrics in the area, such as machine failure rate, downtime, defect rate, and OEE score, highlight the impact of their effort.

• Visual Management/
  Visual Control

  Learn how to organize your workplace, ensure that required work standards and related information are displayed and controls are in place working toward effectively exposing and stopping errors and - even preventing them. In a simple form, participants apply visual display and control techniques to their area or operation - then rank their levels of effectiveness.

• Visual Factory Slideshow

  Examples from Honeywell, Intl. (Mexico)

• Visual Factory Slideshow

  Examples from Master Brand Cabinets, Inc.

• Visual Management Exercise

  A fun way to recognize effective visual control in the workplace.

• Executive VM

  This presentation introduces the benefits of Visual Management techniques and provides several industry examples. Use this presentation to promote Visual Management with your leadership team or to up-sell 5S with a "sister division" within the same company.

• Set-Up Reduction/
  Quick Changeover

  Learn the benefits, goals, and step-by-step activities to achieve "world-class" set-up/changeover times and review over a dozen tips for standardization. After this session, teams incorporate quick changeover through analyzing internal and external work content within a set-up. Examples of tooling, clamping and quick disconnect ideas are provided.

• Set-Up Reduction/
  Quick Changeover Forms

  Use these data collection forms in your Set-Up Reduction team activities.

• Takt Time/J.I.T./
  Cellular Concepts

  Learn the philosophy of "Cellular" production and review three basic components of Just-In-Time (JIT) methodology. Understand the 7 production characteristics of a JIT oriented Cell. As well, basic configurations for work cells and layout proposals are explored.

• Standardized Operations

  Experience the most efficient work combination by learning the 4 elements of a standard operation cycle; the steps and elements of defining standard work; and the documentation required to sustain the gains. During an application exercise, participants demonstrate tool proficiency by utilizing the following data displays for the new improvement idea: Takt time vs. Cycle time Bar Chart, Process Capability Table, Standard Work Combination Sheet, and a Standard Work Layout diagram.

• Kanban

  Use the simple, but powerful Kanban system - where starts equal exits - to synchronize work processes using visual management and visual control techniques. Participants learn the two types of Kanban; operating "Rules" of the Kanban, and several industry examples are presented. P.S There are some great videos about Kanban on YouTube - search"kanban"

• Kanban - Manufacturing     and Production examples

  This module contains pictures of Kanban within Industry.

• Kanban - Types

  This module details the two types of Kanban and their application.

• Push vs. Pull

  The material management concepts of batch and queue versus one-piece flow are explored in this short module.

• Poka-Yoke - Make No Mistake about It

  Reinforce the concept, need, and benefits of error or "mistake proofing" by critically examining the two "states" in which a defect exists, the six steps to mistake-proofing and the ten most common causes of errors. In breakout session, teams develop ideas for controlling defects, improving delivery, and reducing set-up and down times. Several mistake-proofing ideas are provided.

• Poka-Yoke Example 1 (video)

  The need for mistake-proofing.

• Poka-Yoke Example 2 (video)

  Industry examples of Poka-Yoke.

• Project Review Questions

  Don't let your projects die a slow death with little or no results. Use this "Quick toolkit" designed for Project Leaders, Champions, and Mentors to properly assess your progress. Questions to Ask, Pitfalls to Avoid, and Problem Recovery Tips included.

• "Kaizen" - What is It? (Ongoing improvement)

  The Kaizen process is explained in this quick overview. Definition, purpose, and benefits of Kaizen are presented. Sample schedule for a weeklong Kaizen event and examples for the type of projects are provided.

• Kaizen - 5 Day Checklist / Agenda

  Take time to plan your Kaizen event. Use this agenda as your "by-the-hour-chart" (roadmap) for a week-long rapid improvement event.

• All About "Kaizen"
  (Ongoing improvement)

  This material prepares participants to lead a "Kaizen" event from start to finish. Requisite elements covered in the training session include:
  Pre-event activities:
  identifying project need, work area selection, pre-planning concerns and issues, baseline metrics, team formation/ make-up, and opportunity identification.
  Event elements:
  Specific Kaizen training and tool applications, implement improvements and document results. Generation of inexpensive "celebration" ideas.
  Post event concern:
  30/ 60/ 90-day follow-ups. Project management techniques to sustain improvements with documentation and control/ response plans are presented.

• Accountability Meetings

  Learn how successful Leadership Teams use daily accountability meetings, daily planning and scheduling reviews, weekly sales, and operations meetings as the preferred method to drive results. Identify bottlenecks, and share critical "hand-off" information between operating shifts. (Also, see article Accountability Meetings Drive Results)

• PS - Kepner Tregoe

  Comparison of the systematic K-T problem solving approach to several other methodologies (Lecture slides from Jay Watson.)

• PS - DMAIC

  A quick overview of the DMAIC problem solving process is provided.

• PS - 8D

  The eight disciplines of problem solving are detailed in this module.

• PS - 5 Whys

  This problem solving technique drives the team to the root cause of the problem by repeatedly asking why? An example is provided. Also, see article 5 Why Analysis (Forward and Backward)

• Handy Hints for Presenters

  Team members get it when effective presenters give it. Here are some tips and tricks to conduct more productive sessions.

FREE Training Downloads

Use Our Training Modules as a Foundation

Talk about applying the concept of best practice sharing - we're giving it away for free! Don't reinvent the wheel - save tens of thousands of dollars in program development costs - utilize our material.

Our free lean site makes your job easier by offering comprehensive PowerPoint training presentations on a wide variety of safety, quality, and lean enterprise topics:

• The material is foundational, straight forward and simple.
• Each module at the left is designed to be presented in about an hour.
• All presentations are in Microsoft PowerPoint format for easy customization.
• Each module contains learning objectives, definition of the subject, step-by-step instructions, application examples or best practices and a small group exercise at the conclusion.
• Several have key learnings - so don't forget to check the notes pages.
• For their use (and modification), we ask that you please retain the free lean site reference with the materials.
• Think you have what it takes to be a Lean Leader? Click on the "skillset" image above to open a quick self-assessment for Lean Leaders.

Module key points condense foundational Lean Enterprise concepts developed from these three resources. Purchase them to supplement the training material as you rollout your improvement initiative. Click on any of the images below to link to the source for these materials.

Lean Six Sigma Toolbook -Michael George	Lean Enterprise Memory Jogger -Richard L. Macinnes	Lean Thinking -Womak and Jones
FREE BOOK! The Continuous Improvement Companion -Jeff Hajek	FREE BOOK! Guide to Lean Manufacturing -Ron Pereira	FREE BOOK! Lean Manufacturing Basics -Aza Badurdeen
FREE RESOURCES! Training Within Industry (TWI) -Donald A. Dinero