© 2019 Go-Lean-Six Training and Consulting

Onsite Training and Consulting

Go-Lean-Six offers onsite hands-on Kaizen training for one team or your entire company. We come to your location where we not only educate your people, but we put that knowledge to work during the training to be sure you have a great start to Lean or to take your company to the next level in your Lean journey. 

You will see immediate benefits.

Contact us today to book a free training consultation.

Email: info@Go-Lean-Six.com   or   Phone: 717-495-2699

 
 

Introduction to Lean Workshop

 

 

Intro to Lean Principles 

 

Manufacturers must reduce costs to remain competitive and improve profits in today’s market place. Industry needs leaders skilled in identifying and eliminating waste within manufacturing and administrative processes. Employers benefit from training their employees in how to identify and eliminate unnecessary costs. One method of achieving this goal in a short period of time is through classroom participation and instruction in understanding Lean principles. Lean seeks to highlight and then eliminate unnecessary events that are not value added in the eyes of the customer.


A Lean implementation will reduce product cycle times, excess inventories, excess floor space, defects, set-up and other hidden process costs. Your organization will have less dependence on third party experts. This training is designed to be transferable between many industries and environments.  


This eight hour intro would be used as a companion course to prepare the participant for additional advanced training in Value Stream Mapping, 5-S Workplace Organization, Cellular Manufacturing, Quick Changeover, TPM- Overall Equipment Effectiveness, Kanban (Pull System), Kaizen and other related value added workshops developed by Productivity Inc.

Value Stream Management Workshop

 

 

Eight Steps to Planning, Mapping & Sustaining Lean Improvements

 

Value stream management is about more than just mapping your value stream and making a few improvements. A successful, sustainable lean initiative requires a process to manage the entire lean transformation. This workshop will teach you an exciting eight-step method for creating and applying a systematic process for the implementation of lean. You will actually be able to train lean teams in the process and begin using it immediately. Plus, you will see how leading American manufacturing facilities have accomplished their lean transformation. This workshop starts with an overview of value stream management and the basics of lean. Subsequent lessons will teach you how to map your current state; how to plan and map your future state in three stages — demand, flow, and leveling; how to create action plans for implementation and follow-through; and how to develop a storyboard that communicates the entire process.  

 

Step 1: Commit to Lean
Step 2: Choose the Value Stream
Step 3: Learn about Lean
Step 4: Map the Current State
Step 5: Identify Lean Metrics
Step 6: Map the Future State
Step 7: Create Kaizen Plans
Step 8: Implement Kaizen Plans

 

5S Workplace Organization Workshop

 

 

Five-S Workplace Organization Workshop

 

The 5S workplace organization workshop is designed to deliver the fundamental concepts of 5S to your workforce so your organization can begin putting this powerful system to work. Sort, Set in Order, Shine, Standardize, Sustain. Together, these five simple principles form the basis of the 5S System. 5S is a powerful front-line tool for simplifying work processes, improving equipment maintenance, ensuring safety and product quality and eliminating waste. 5S is the basis for any on-the-floor improvement activity and the 5S for Associate's Learning Workshop is a fantastic way to bring that knowledge to the shop floor.

Black Belt Training Course

 

Black Belt Course

 

A Black Belt has expert knowledge and skills related to the DMAIC methodology. This Lean Six Sigma DMAIC course prepares participants for the role of a Lean Six Sigma Black Belt. This workshop is a comprehensive training covering everything within the Lean Six Sigma D-M-A-I-C body of knowledge required to successfully prepare to achieve Black Belt certifications and performance standards. This will enable you to achieve, sustain and maximize business success.

 

We will be teaching theory, supplemented with real-world workable examples in every section with Kaizen events so you can immediately apply what you have learned to your work environment. Six Sigma is driven by a close understanding of customer needs, using facts, data, statistical analysis, and diligent attention to managing to improve and reinvent your business processes. Contact Go-Lean-Six to discuss scheduling this workshop.

Green Belt Training Course

 

Green Belt Workshop

 

A Green Belt has strong knowledge and skills related to DMAIC methodology and Lean methods, they have graduated from Yellow Belt but typically don’t have experience and advanced statistical tools such as design of experiments that a Black Belt will have. Green Belts may lead simple projects under the guidance of a Black Belt or may work as a team member on a large project team.

 

We will be teaching theory, supplemented with real-world workable examples in every section with Kaizen events so you can immediately apply what you have learned to your work environment. Six Sigma is driven by a close understanding of customer needs, using facts, data, statistical analysis, and diligent attention to managing to improve and reinvent your business processes. Contact Go-Lean-Six to discuss scheduling this workshop.

 

Yellow Belt Training Course

 

Yellow Belt Workshop

 

A Yellow Belt is trained in the general Lean Six Sigma DMAIC concepts and basic tools. This Lean Six Sigma DMAIC course prepares participants for the role of a Lean Six Sigma Yellow Belt. This Lean Six Sigma is comprehensive curriculum covering everything within the Lean Six Sigma D-M-A-I-C body of knowledge required to successfully prepare students to achieve Yellow Belt certifications and performance standards.

 

We will be teaching theory, supplemented with real-world workable examples in every section with Kaizen events so you can immediately apply what you have learned to your work environment. Six Sigma is driven by a close understanding of customer needs, using facts, data, statistical analysis, and diligent attention to managing to improve and reinvent your business processes. Contact Go-Lean-Six to discuss scheduling this workshop.

 

Healthcare Lean-Six Black Belt Training Course​

Healthcare Lean-Six Black Belt Training

 

This Lean-Six Black Belt course is a good fit for the healthcare industry. Lean principles, strategies and techniques work well in hospitals, insurance companies, and other healthcare facilities. It is excellent for VPs, Department Directors, Managers, RNs, Technologists, Therapists, Accounting, Quality Improvement Specialists and Ancillary Personnel. The course consists of intensive hands-on exercises including the completion of a real-world Lean Six project at your facility bringing immediate results. The Black Belt course training schedule and modules can be tailored to fit your needs.

 

Applying Lean Six can help you to:

 

  • Increase your bed capacity by up to 15% without increasing the number of beds.

  • Reduce the errors by up to 50% without increasing costs.

  • Delight your patients, doctors, and employees with unparalleled improvements.

  • Put your own career on fast track by gaining Lean-Six skills made famous by GE.

 

Some of the concepts covered include:

 

  • What is Lean-Six?

  • Continuous Improvement

  • Is “99% Error Free” Enough?

  • Cost of Poor Quality

  • The Eight Steps of Value Stream Management

  • Strategic Management and Policy Deployment system, called Hoshin Kanri

  • 5-S Plus Safety Workplace Organization

  • Daily Visual Management. (Daily Huddles and Visibility Tools)

  • Lean-Six Deployment and Roles

  • Voice of the Customer (VOC) and Kano Diagram

 

Our primary instructor for this course is Arvind Salvekar, Ph.D. who is a fellow of HIMSS and has been applying Lean-Six principles in healthcare for the last 35 years.

Lean Enterprise Steering Team Workshop

 

 

Creating a roadmap for your lean journey


Every enterprise serious about launching a successful lean journey must establish a lean implementation plan (Lean Road Map). The best way to accomplish this objective in a short period of time is to through the Lean Enterprise Steering Team Workshop. The Lean Enterprise Steering Team is responsible to provide support in measuring, training, planning, funding, staffing and prioritizing continuous process improvement events. The steering team consists of inter-departmental top managers who understand the business goals and are committed to the Lean Journey. 

 

Participants will answer implementation questions such as

• What will be the benefits of lean? What will be our Return On Investment?

• How will we align our lean efforts to the overall business objectives? 

• What are the specific steps to implementing lean (Lean Roadmap)?

• How do we clearly define and communicate the company mission? 

• How will we measure and sustain our lean progress? 

• How will we communicate our commitment to lean across the organization?

• How do we change the culture to institutionalize continual improvement?

• How do we charter lean transformation teams?

• Should we have a no lay-off policy?

• How will we reward and recognize team accomplishments?

 

 

Leader, Facilitator and Coach Workshop

 

Empowering leaders with the tools to facilitate ongoing process improvements

 

Industry needs champions skilled in leading effective teams on and off the floor as they identify and eliminate waste within manufacturing and administrative processes. Industry faces a shortage of skilled leaders able to facilitate the lean culture change. Leaders need to coach and train their employees how to identify and eliminate unnecessary costs. One method of achieving this goal in a short period of time is through classroom participation in Lean / Six Sigma Leader, Facilitator, and Coach Workshop. This training is designed to be transferable between many industries and environments. This two-day course will prepare your internal leaders to become the champions of your Lean and Six Sigma culture change.

 

Topics:

Leading the culture change

Identifying Projects

Chartering Lean Project Teams

Chartering Lean Continuous Improvement Teams

Effective Team Meetings

Team Meeting Minutes

Leader Duties

Facilitator Duties

Recorder Duties

Member Duties

 

 

Mixed Model Kanban Workshop

 

Lean Replenishment Technique for Pull Production

 

Implementing a Mixed Model Kanban System is a comprehensive and in-depth guide to implementing a kanban within the value stream. Its plain-language approach provides step-by-step coverage and guidance of the implementation, metrics and dynamics of an effective kanban system based on proven reliable methods honed through years of implementation experience within manufacturing and non-manufacturing environments. By focusing on a case study of a manufacturing company trying to create and maintain continuous flow in their value stream, Vatalaro and Taylor show how to construct your own kanban process, from beginning to end.

 

Topics:

• Preparation Work

• Introduction to kanban systems

• The numbers (Kanban Calculator)

• Some Tools to help you “Go-Do”

• Kanban Glossary

• Kanban Pilot

 

 

Flow Cells - Continuous Flow Workshop

 

Flow for Work Teams


Introduces production teams to Cellular Manufacturing; A process which involves rearranging traditional operational-based factory and office layouts into process-based cells that promote smoothing information and production flow by cutting waste. This learning package introduces production teams to basic cellular manufacturing and teamwork concepts and orients them for participating in the design of a new production cell.

 

You will learn:

• Waste reducing benefits of organizing the workstations in cells, so that work flows smoothly in the process sequence.

• What to expect when you work in a manufacturing cell--a U shaped arrangement, minimal inventory, moving with the work and multi-machine operation.

• Steps you will experience as you design and convert to a cellular arrangement.

• About Takt Time and standardized work

TPM Overall Equipment Effectiveness Workshop

 

 

Shop-floor Autonomous Maintenance

 

This workshop provides operators, supervisors, team leaders and TPM coordinators with useful guidance for autonomous maintenance.

 

TPM leads to soaring productivity when your operators are positively and energetically involved in the maintenance of their own equipment. Autonomous Maintenance for Operators teaches specific autonomous maintenance activities.

 

For operators, supervisors, team leaders and TPM coordinators, this workshop provides useful guidance and examples on autonomous maintenance. Activity boards, one-point lessons, photos and actual examples of implementation demonstrate the huge benefits of developing informed, motivated operators who take ownership of and improve their equipment.

 

Participants will learn:

• 4 skills they can develop to keep equipment running smoothly.

• How to inspect for problems as they clean equipment.

• Ideas for containing debris that shortens equipment life.

• Tips for effective lubrication management.

• How to use activity boards, meetings and one-point lessons to promote TPM goals.

 

 

Quick Changeover Workshop

 

The SMED Quick Changeover System

 

Quick changeovers are critical for any company wanting to practice just-in-time or one-piece flow manufacturing, since models may be rapidly switched and unneeded inventory may be avoided. SMED reduces difficult, time-consuming and wasteful activities in your company, which ultimately supports your company's competitiveness and makes your own work much easier. The SMED system you'll learn in this workshop is the most effective approach for shortening changeover time. 

 

The SMED approach is actually quite simple and universal. Companies all over the world practice it. First used in (and named for) manufacturing with dies, SMED's basic principles have helped reduce setup and turnaround time in all types of manufacturing, assembly and even service industries. 


SMED is really about observing, thinking and acting on improvements to changeover. You observe how things are done presently, you think about and note how the situation can be improved, and then you  work on how the necessary setup work can be done in the shortest possible downtime.


In this workshop the team learns:
The four set-up steps. 
How to analyze and continuously reduce set-up time on your equipment.
How to separate external events from internal events.

 

Root Cause and Corrective Action Workshop

 

 

Technicomp’s Corrective Action program

 

This workshop teaches employees how to use a simple, effective 8-step approach to correcting – and preventing – problems or nonconformities that exist anywhere in their organizations. It can help to satisfy quality management system requirements for planning and establishing a process for corrective action. 

 

Topics  

-Determining Ownership 

-Defining the Problem  

-Isolating and Containing the Symptoms  

-Root Cause Analysis  

-Identifying and Verifying an Effective Corrective Action  

-Implementing and Validating the Corrective Action  

-Taking Preventive Action to Avoid Potential Problems  

-Acknowledging the Improvement

 

Kaizen for the Shop-floor Workshop

 

Continuous Improvement Event

 

Prepare your entire workforce to truly benefit from your next kaizen event! Now you can give your frontline employees the information they need to understand, plan, and implement kaizen.


The philosophy of kaizen, which simply means continuous improvement, is the starting place for all lean production improvements. Kaizen events are opportunities to make focused changes in the workplace. Kaizen for the Shop-floor takes you through the critical steps in conducting a very effective kaizen event - one that is well planned, well implemented and well documented. As the newest addition to the Shingo Prize Winning Shop-floor Series, Kaizen for the Shop-floor distills the complexities of jumpstarting lean processes into an easily accessible format for the frontline employees who make lean possible. 


This workshop
• Follows the seven steps of kaizen
• Provides learning strategies and overviews in each step 
• Details the planning and preparation stages for kaizen events 
• Maps out the implementation process 
• Offers tips on how to present your results to company management

 

Lean Office Value Stream Workshop

 

 

Eight Steps to Planning, Mapping & Sustaining Lean Improvements in Administrative areas

 

Administrative Value stream management is about more than just mapping your information and product value streams and making a few improvements. A successful, sustainable lean initiative requires a process to manage the entire lean transformation. This workshop will teach you an exciting eight-step method for creating and applying a systematic process for the implementation of lean. You will actually be able to train lean teams in the process and begin using it immediately. Plus, you will see how leading American companies have accomplished their lean transformation.

 

This workshop starts with an overview of value stream management and the basics of lean. You will map your current state and map your future state. You will learn the three stages — demand, flow, and leveling; how to create action plans for implementation and follow-through; and how to develop a storyboard that communicates the entire process. 

 

Step 1: Commit to Lean
Step 2: Choose the Value Stream
Step 3: Learn about Lean
Step 4: Map the Current State
Step 5: Identify Lean Metrics
Step 6: Map the Future State
Step 7: Create Kaizen Plans
Step 8: Implement Kaizen Plans

 

Lean Boot Camp

 

Go-Lean-Six Lean Boot Camp

 

Go-Lean-Six Lean Boot Camp is an intensive Lean training. The training prepares people to use Lean methodology and Lean tools. The entire program is tailored to help businesses reduce the cost of safely delivering, quality products and services on time. This practical training, filled with real-world examples and exercises, is aimed at generating results. Participants will be able to use their new knowledge and skills immediately to make processes flow simpler, faster, better, and less costly. They will build their lean toolkits by way of a real-world kaizen project. The boot camp is perfect for people who work in manufacturing or office environments. The training schedule and modules can be tailored to fit your needs.

 

Training modules include:

 

  • Introduction to lean principles

  • 5S – Workplace Organization 

  • The eight steps of value stream management

  • Kanban – pull systems

  • Quick Changeover (SMED)

  • Creative Problem Solving (RCCA)

  • Total Productive Maintenance

  • Kaizen (Continuous Improvement)

  • Lean Office

  • Leader – Facilitator – Coach

  • Lean Six Sigma – Deployment Strategy

 

 

Lean Facility Layout Services:

Go-Lean-Six Lean Facility Layout Services:

 

Your business is growing, you’ve made the decision to expand your facility and you’d like the new plant to be lean and efficient.  The new (or the existing) layout should be based on fulfilling customer orders and doing so efficiently.

 

Most companies have growing pains, and these problems are manifested in wasted motion, extra transportation, too much inventory and a lot of extra expenses. Machinery is often placed where you have space, not where it makes sense.  Don’t build the old inefficiency into the new factory.

 

We will work with your staff to optimize inventory flow and equipment placement.  We will teach your staff the lean strategies and techniques such as value stream mapping and 5-S methodology…. Go-Lean-Six has helped entrepreneurs as well Fortune 500 companies improve their layouts and optimize their facilities for success.

 

Contact Go-Lean Six today to begin the discussion on your Lean facility layout. Call 717-495-2699

 

Capacity Increase (Cost Avoidance) Services 

 

Capacity Increase (Cost Avoidance) Services:

 

You can get significantly more production from your existing plant.  Please contact us BEFORE you spend money for more capacity.

 

When manufacturers are maxed out on space, people, machinery, and processes, the traditional approach is to double everything…including the inefficiency and the operational waste.  The capital expenditure will work, but it’s also a very expensive option.  There’s a better approach:  Go-Lean-Six can help your team find significantly more capacity without adding resources.

 

For instance, we helped a major food company increase capacity by 33% while reducing labor hours 22%.  They did so without the cost of building a new facility, hiring more employees, buying machinery and paying all the ancillary costs of maintenance, utilities, taxes and insurance.

 

Our proven methodology includes lean principles and tools such as value stream mapping, 5S workplace organization, quick changeover and constraint analysis, along with AutoCAD drawings to layout your optimized and extremely efficient new process.  We also train and coach your staff to continuously improve your operation as they optimize employee flow, inventory flow, equipment placement and line design.

 

And the fringe benefit….telling your customers you’ve dramatically shortened your lead times.

 

Call us to learn how an implementation of Lean Principles can help you avoid a major capital expenditure.  Call 717-495-2699

 

Lean Knowledge Work

 

Lean as Applied to Knowledge Work:

 

Lean is successfully applied to knowledge work to continually root out and remove waste resulting in faster response times, higher quality and creativity, lower costs, and greater job satisfaction. Knowledge workers are workers whose main capital is knowledge. Examples include software engineers, physicians, pharmacists, architects, engineers, scientists, design thinkers, accountants, lawyers, and academics, and any other white-collar workers, whose line of work requires one to "think for a living". 

 

Go-Lean-Six has successfully implemented Lean in knowledge work environments such as research and development, laboratories, engineering and many other transactional knowledge work based enterprises.     

 

Call us to learn how Lean Principles apply to your knowledge work environment.  Call 717-495-2699

 

 

Lean Relocation Services

The Go-Lean-Six Team can provide services to assist you in relocating individual work cells or your whole company. We can assist in analyzing your current work cell or production line, creating a Control Plan(s), producing PFMEAs to mitigate risks, redesigning the line to world-class Lean levels, and implementing the install and start up - all while keeping safety, quality, delivery and cost in mind.

 

We have a quick response team ready to assist you in moving one cell or a whole organization. The team will use PFMEA’s and Control Plans to address quality, on-time delivery as well as cost issues and the associated risks. The consultants follow the work cells from one location to the other setting up “continuous flow” lean manufacturing cells using Lean Statistical Cell Design Techniques. Contact Go-Lean-Six for a free assessment of your relocation needs. 

 

Healthcare Lean Training

Go-Lean-Six is offering Yellow, Green and Black Belt Training for the healthcare industry. We have worked with several hospitals to train their staff on key Lean Six principles. Go-Lean-Six provides hands-on workshops where learning is applied to areas in need of improvement. We often divide the class in several groups to tackle several projects at a time. In this way, the organization receives the benefit of dozens of completed projects during the belt training often paying for the training and then some. We have coached them in tackling customer-facing projects such as patient flow in and out of the emergency department as well as behind the scenes projects, like mailroom organization.

Over the past dozen or so years, Lean & Six Sigma has taken healthcare by storm. The healthcare industry has taken their past issues with safety, quality, long wait times and high cost by the horns using Lean-Six. They have used Lean to help solve issues from changing over an exam room to unacceptable life-threatening incidents in surgery with remarkable results. Some have achieved the goal of not having an ER waiting room, instead keeping the patient “standing” and moving through the process. They are achieving record times getting their patients in and out of the ER. Others have gone after the root cause of hospital-acquired diseases finding creative ways to significantly reduce these incidents. They have come to see that any process can be improved, whether they are figuring out how to prepare hospital surgical tool trays error-free and in a timely manner or reducing the incidents of patients staying longer than their insurance pays for. They are tackling these and many more issues with the process improvement tools of Lean Six Sigma.