Achieve results by building on OPEX Tools



You want to strengthen your team’s hands-on capabilities to master the next challenge?

As dedicated practitioners we like to roll up our sleeves and become part of your team to work on improvements. Our training workshops are tailored towards meeting the needs of your specific group or organization. These are interactive trainings with a strong focus on delivering results while ensuring the appropriate tools are selected and learning takes place by action and reflection.

We encourage our training participants to immediately apply the acquired skills to their own process improvement project, always addressing a significant business need. We share our implementation experience in Lean Six Sigma methods focusing on regulated environments.

Contact us! We are happy to explain how our practical approach to competence building help to achieve results.

Our Training Workshops:

  • Toyota Kata
  • Lean Implementation Expert
  • Train-the-Trainer
  • Shopfloor Problem Solving
  • Root Cause Investigation
  • Statistics for APQR / CPV [Life Sciences]
  • Design Excellence

1 day

Location: On your site
Capacity: 4-8 participants
Price: € 2,500

Toyota Kata Awareness

Toyota Kata is a leadership approach and style. It helps to turn around the dynamics of an organization and generates improvement bottom-up while setting challenges top-down. It prevents enthusiastic Lean leaders from the typical phenomenon of generating a lot of initiatives in production without prioritizing them. Toyota Kata applied in the right way can be very motivating and inspiring.

Workshop Outcome
Understanding the idea of Toyota Kata and its benefits for your organization
First experience and find leadership inspiration by applying Toyota Kata


Workshop Program

Get an overview of our suggested approach to implement Toyota Kata, how to use the needed templates and practice during the training

  • Background: What is Toyota Kata
  • Improvement and coaching Kata
  • Kata training in the Classroom “KiC”
  • 6 steps after training
  • Kata cascade to break down challenges
  • Schedule for coaching Kata cycles
  • Kata approach check-up
  • Work with typical Toyota Kata tools like coaching plan, 5 questions & 4 steps, Kata board
  • Practice Kata coaching techniques
  • Move to action: Where to implement Toyota Kata and implementation plan

For whom:
For leaders in all environments

Bring your own challenge


Key Features

  • Effectively strengthen your leadership skills through experimenting with methodologies, role plays and feedback
  • Key success factors to implement Toyota Kata: a strong coach-trainer relationship and practices within the real shopfloor environment

Lean Implementation Expert

Implementing Lean and supporting Lean transformations requires project leaders with versatile skills: It’s about enthusing and convincing people on all levels of the organization, it’s about managing projects and change. The ability to build on right methods and approaches determines success.

Workshop Outcome
Experience of the key Lean methods
Successfully solved business challenge
Capabilities for repeated success developed on site


Scoping (0.5-1 days, free of charge) Definition of business problems to solve

Preparation activities

Session 1 (2 days)

Training: Setting up projects and Kaizen workshops, facilitation skills, basic Lean tools like 5S, 7 Types of Waste and PDCA Preparation: Schedule meetings for implementation support with coach

Individual project support (1 day per project) Hands-on support by consultant on your site

Session 2 (3 days)

Deeper into scoping and executing the projects, Lean metrics, OEE, Gemba, process mapping, Value Stream analysis, standard work and SMED

Individual project support (1 day per project) Hands-on support by consultant on your site

Session 3 (2 days)

Deep dive into methods to support leaders and make success sustainable like Performance Management, 1-2-3, problem solving, Flow, Pull and Kanban

For whom:
Those dedicated to driving improvement and with a career plan to professionally support their organization with Lean

Bring a challenge or a project

Certification as Lean Implementation Expert for successful implementation

Key Features

  • ROI of typically 5:1 within one year
  • Great addition to Lean transformation programs
  • Selection of tools specifically tailored to you

7 days training +
2 days support per participant

Location: Hamburg
Capacity: 3 – 5 participants
Price: € 7,500 p.p.

2 days

Location: On your site
Capacity: Max 4 participants
Price: € 5,000 per workshop


Implementing Lean requires to train people on all levels of the hierarchy. Thereby, the quality of the training itself represents a first success factor. Trainings need to be adapted regarding the deepness of theory. They should be exciting, practical and fun to ensure a lasting learning experience. This training workshop establishes the capabilities to get there.

Workshop Outcome
✓ Developed capabilities to run excellent in-house trainings on Lean topics


Workshop Program (2 days)

Teach-backs with lots of feedback are built in throughout the day

  • Purpose of Lean trainings
  • Defining learning objectives
  • Preparing a training
  • Structuring a module to be interactive
  • Generating the Lean experience

Typical Tools & Methods

We recommend to prepare one of these topics:

  • Waste and Value
  • 5S
  • Standard Work
  • Yellow Belt simulation

For whom:
Future inhouse trainers

Bring a training module you want to facilitate


Key Features

  • Very small groups for the best training experience

  • After receiving valuable input you will have the opportunity to practice your trainer skills and receive qualified feedback

Shopfloor Problem Solving

On the shopfloor, most people understand a goal once they have started to
work on it. Thus, problem solving is at the core of motivating people to achieve goals. The training will help to greatly develop self-confidence and motivation. It will also generate ideas for improvements and show when to rely more on systematic problem solving.

Workshop Outcome
✓ Capabilities to solve real problems quickly and sustainably
✓ Implement a culture of reviewing root causes instead of jumping to solutions


Workshop Program (2 days)

  • Discover the power of systematic problem solving
  • Tools to identify root causes
  • Exercise root cause identification and experience the effect
  • Implement the solution and make it sustainable

Typical Tools & Methods

  • Problem definition
  • PDCA
  • Fishbone (Ishikawa)
  • 5W1H
  • Action Plan
  • Visualization
  • A3

For whom:
Everyone to be involved in systematic problem solving, typically operators, technicians, team leaders
from production, engineering, assembly

Select real shopfloor problems to be tackled during the training


Key Features

  • Fun and revealing case everyone can relate to

  • Highly interactive through intensive group-work and real-time problem solving

2 days

Location: On your site
Capacity: Max 8 participants
Price: € 5,000 per workshop

2 days

Location: On your site
Capacity: Max 12 participants
Price: € 5,000 per workshop

Root Cause Investigation

Especially in regulated environments, it is important to efficiently identify
and document the root causes of deviations. At the same time, truly understanding the root cause provides an opportunity to stabilize and improve your processes. Not being able to release a batch due to an open deviation could be an expensive, nonetheless, often avoidable issue.

Workshop Outcome
✓ Systematic and thorough identification of root causes of complicated deviations
✓ Increase efficiency and sustainability of closing deviations


Day 1

  • Introduction and expectations
  • Overview of the investigation
  • Lessons Learned from deviations rRCI discovery case
  • Root Cause Investigation thought process template
  • Problem Statement
  • Is/Is Not & timeline
  • Distinctions/changes
  • Fishbone/ 5 Why’s
  • Contradiction Matrix
  • Confirm true cause

Day 2

  • Presentation of practice case
  • Solving the case in groups
  • Solving cases from your site
  • Closure, evaluation next steps

    For whom:
    Leaders of deviation/ root cause investigations, Quality, QA

    Bring an open investigation case with related documents ready

    Certification of participation and closing deviation

    Key Features

    • Experienced support during investigation of current and open cases from your site

    • Highly interactive through intensive group-work and real-time deviation investigation

    • Specific to industries where addressing a deviation must also be documented, such as Automotive, Aerospace or Life Sciences

    Statistics for APQR / CPV

    The expectations of health authorities regarding the use of statistics in Annual Product Reviews, Product Quality Reviews and Continued/Ongoing Process Verification (APR / PQR / CPV / OPV) have increased.
    Historically it was enough to be “inside the spec limits”, today producers are expected to explain their product’s variation using Control Charts and Ppk.

    Workshop Outcome
    ✓ Application of statistical principles to assess product behavior and performance

    ✓ Working more efficiently by only doing the relevant calculations


    Day 1 – Basic Statistics

    • Types of data
    • Types of distributions
    • Sample size confidence
    • Measurement systems

    Day 2 – Process Analysis

    • Process stability
    • Process capability
    • Capability Sixpack

    Day 3 – Cause-Effect Analysis

    • Hypothesis testing
    • Simple Linear Regression

    You will also learn to effectively visualize statistical conclusions and summaries, allowing for efficiency in reading reports and clarity for decision-making.

    For whom:
    Everyone preparing or supporting product reports

    Laptop with MINITAB, process data must be sent to the trainer before the course (can be anonymized)

    Certification of participating in training and about tools learned

    Key Features:

    • studies from the Life Sciences
    • Statistics become easy to work with and even fun!

    3 days

    Location: On your site
    Capacity: Max 12 participants
    Price: € 7,500 per workshop

    1 day

    Location: On your site
    Capacity: Max 12 participants
    Price: € 2,500 per workshop

    Design Excellence Awareness

    Design Excellence is the concept of developing new products in a way to
    balance quality (what does the customer want?) and manufacturability – (what can we produce efficiently and effectively?). To meet this balance, it is important to manage the design flow in both directions and simultaneously, consider requirement management and robust design.

    Workshop Outcome
    ✓ Awareness of Design Excellence and its implications for your role
    ✓ Understanding the flow of the Design Excellence tools and how they work together, especially in the context of the Design Control process


    Workshop Program (1 day)

    Design Excellence background

    Design Excellence within a typical new product introduction process

    Design Excellence simulation

    Design Excellence tools like requirements identification and prioritization, Design Excellence Scorecard, product and process risk analysis, basics on process capability and control

        For whom:
        Line Management affected by development projects from Marketing, R&D, Operations, Life Cycle team leaders, Project leaders and R&D project team members


        Certification of participation and closing deviation

        Key Features

        • Use of a fun Lego simulation to illustrate Design Excellence concept and tools

        Download a PDF copy of our complete Training Catalogue for 2020.

        OPEX BELTS

        Do you love to drive improvement? Become a certified process improvement expert and change your workplace for the better.

        To create the best possible training experience tailored to the needs of your organization, each of our programs starts with understanding your challenges, demands and goals. The special feature in all our trainings: immediate application of the achieved skills to a process improvement project addressing a significant business need for your company. We provide advice on project selection and individual coaching during project progression. Upon successful completion of your improvement project, you will obtain our well-recognized certification as OPEX / Lean Six Sigma Belt.

        Our OPEX Belts:

        • Yellow Belt
        • Green Belt
        • Black Belt Bridge
        • Master Black Belt
        • GB/ BB refresher

        Upon request

        Location: On your site
        Capacity: 16 participants
        Price: Upon request

        Yellow Belt

        You would like to increase your service quality and improve your operational processes? Enable everyone in your organization to support a process improvement initiative and raise awareness for Operational Excellence. Yellow Belt trainings provide the perfect opportunity to reach many people and communicate Lean Six Sigma basics to work in a strong customer- & result-oriented way.

        Training Outcome
        Confidence to explain the idea of Operational Excellence and Lean Six Sigma to colleagues
        Ability to contribute to a process-improvement project


        Training Program (1 day)

        • Introduction and Expectations
        • Simulation Round 1
        • Introduction to OPEX
        • Problem Definition
        • High level process mapping
        • Voice-of-Customer & CTQ
        • Value-Added Flow-Analysis

        • 5 Why
        • Simulation Round 2

        Depending on your improvement program, audience and available time, this training can be enhanced to two or three days by adding more of the basic tools. For longer trainings the simulation rounds will be distributed over the days to maintain a high level of engagement.

        For whom:

        Everyone to be involved in process improvement projects, typically subject-matter- experts, managers, process owners and team members

        Preparation: None

        Certification: Yellow Belt certification

        Key Features

        Interactive and fun Pizza delivery simulation to make the concepts & tools tangible and to increase the motivation in the organization

        Green Belt

        You would like to execute a process improvement project with Lean Six Sigma tools? Achieving significant performance improvements is crucial for the future competitiveness while requiring time, energy and communication. Green Belts are experts in solving process problems with the efficiently structured, fact- based project approach DMAIC, focusing on sustainability.

        Training Outcome
        The numerous skills needed to lead DMAIC projects


        Part 1 (3 days)

        Basics: DMAIC, problem definition, customer focus, project management, statistical thinking
        Quick-Win techniques: 7 Wastes, 5S
        Data-based process analysis: Process mapping, Lean metrics, discrete measurement system analysis, data collection, qualitative root cause analysis
        Data-based process monitoring & validation: Control Charts, process capability calculations

        Part 2 (3 days)

        Quantitative root cause analysis: Basic hypothesis tests, simple linear regression
        Process improvement: Dogma Busting & Blue Sky, Standard Work, Poka-Yoke, Visual Management, Flow & Pull

        Part 3 (3 days)

        Sustainable implementation: Mitigating risks, agile implementation principles, PDCA for continuous improvement
        From project to daily business: Process- check-on-site, statistical process control, roles and responsibilities, project close-out
        Training closure: Final recap, exam and take- aways

        For whom:
        Everyone with a passion to improve processes

        Process requiring significant improvement, laptop with Minitab

        Certificate of attendance after completion of the exam, Green Belt certification after successfully completed GB-project

        Key Features

        • Learn through direct practical application in interactive simulations and exercises
        • Measurable business results from leading a Green Belt improvement project
        • Receive support with project selection and coaching throughout training

        9 days

        Aug 25-27, Sep 22-24, Oct 20-22
        Location: Hamburg / Virtual Classroom
        Capacity: 12 participants
        Price: € 5,700 p.p.

        10 days

        Mar 31-Apr 2, May 4-7, Jun 2-4 Location: Hamburg Capacity: Max 9 participants Price: €6,500 (€4,300 if booked with GB)

        Black Belt Bridge

        As a Green Belt you have already experienced the power of Operational Excellence during previous process improvement projects and training. Take this to the next level and tackle higher value projects: multiple stakeholders, difficult data analysis, more complexity! Learning the advanced tools and roadmaps not just helps you to succeed, but also to coach Yellow and Green Belts.

        Training Outcome
        Strengthened expertise and repertoire
        Ability to select most efficient roadmap / tools for each scenario in operations


        Part 1 (3 days)

        Project selection: 1-2-3 Model, Value Stream Mapping, Voice-of-Customer and demand analysis, OPEX business cases

        Data-based process analysis: Additional distributions, transformation, continuous measurement system analysis, gage linearity, baseline analysis for non-normal data

        Part 2 (4 days)

        Quantitative root cause analysis: Power & sample size, advanced hypothesis tests, multiple non-linear & logistic regression

        Finding best solutions: Creativity techniques and facilitation, Design of Experiments (DOE), Monte Carlo simulations

        Part 3 (3 days)

        Leadership & Change: Setting up Shopfloor Management for continuous improvement

        Data-based process control: Sustain change with monitoring for all types of data

        Specific roadmaps: IDOV/DFSS, Kaizen, RCA, SMED, OEE, Lean Lab, Lean Transformation

        Training closure: Final recap, exam and take-aways

        For whom:
        Part- and full-time improvement experts who lead complex projects and coach other improvement project leaders

        Green Belt certificate, complex improvement project, laptop with Minitab

        Certificate of attendance after completion of the exam, Black Belt certification after successfully completed BB-project

        Key Features

        • Strengthen your leadership and facilitation through teachbacks
        • Measurable business results from leading a Black Belt improvement project
        • Receive support with project selection and coaching throughout project lead

        Master Black Belt

        A Black Belt knows how to manage cross-functional projects. As Master Black Belt, there is a stronger focus on leading employees, business processes and functions. As drivers of OPEX Deployments and working directly with site management, Master Black Belts have both: a solid foundation in advanced methods as well as the ability to drive change on the highest level.

        Training Outcome
        Highest level of OPEX expertise Prepared for leading OPEX across a business


        Day 1 – Leadership Skills

        • Role of the MBB
        • Coaching project sponsors
        • Facilitating site leadership decisions

        Day 2 – Advanced Statistics

        • Multiple curvi-linear regression
        • Recap & Advanced DOE

        Day 3 – Opportunity Identification

        • Lean Management Systems
        • Financials for OPEX Leaders

        Day 4 – Setting up for Success

        • Strategy Deployment
        • Portfolio Management
        • Specific topics of interest
        • MBB Exam Preparation

        Day 5 – Exam (4 hours)

        • 100 Multiple Choice questions on OPEX
        • 10 open questions on approaching different project situations
        • 3 case studies using advanced statistics in Minitab to conclude practical advice

        Follow up Coaching (4 hours)

        • Session 1: Exam review
        • Sessions 2-4 per individual choice

        For whom:
        Site- & Global OPEX leaders who want to become or improve as MBBs

        Laptop with Minitab, Black Belt certificate, portfolio of led and coached OPEX projects

        MBB certification requires successfully completed projects solving complex problem, 10+ coached OPEX projects, co-delivery of BB training and having advanced OPEX in one’s company

        Key Features

        • Final agenda will be tailored to the needs of this small expert group

        • Ample networking and exchange built in to allow benefitting from the deep expertise of fellow participants

        5 days

        Oct 12-16
        Location: Hamburg
        Capacity: Max 8 participants
        Price: € 4,000 p.p.

        2+2 days

        Jul 14-15, Jul 16-17
        Location: Hamburg
        Capacity: Max 8 participants
        Price: €1,400 (€2,500 for both refreshers)

        Green & Black Belt Refresher

        You were certified many years ago and, maybe after a pause in OPEX work,
        you would like to refresh your knowledge? Or recap the tools before pursuing
        the next level of certification? Learning about the latest additions to the OPEX toolkit and exchange with other experienced practitioners sounds like a good idea? Then join one or both of our refreshers – Either way the training will be tailored to address your most pressing questions.

        Training Outcome
        ✓Refreshed and deepened understanding of the most relevant tools


        Part 1 (2 days) – Green Belt Refresher

        Basics: DMAIC, project management, customer focus

        Data-based process monitoring & validation: Basic statistics, selecting metrics, Control Charts, process capability calculations

        Selected OPEX tools: Determined by participants’ needs, typically includes Lean metrics, value added analysis and hypothesis testing

        Part 2 (2 days) – Black Belt Refresher

        Basics: Various OPEX roadmaps, 1-2-3 Model

        Leadership: Engaging stakeholder, training, coaching, facilitating

        Selected OPEX tools: Determined by participants’ needs, typically including advanced data analysis tools

        For whom:
        Green & Black Belts

        Laptop with Minitab

        Certificate of attendance displaying list of topics

        Key Features

        • Refreshed tools will include the ones most relevant for you

        • Work on your most critical OPEX problems during the training

        • Exchange with experienced practitioners

        • Individual coaching opportunity

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