LEAN WORKSHOPS

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

Preparation:
Bring your own challenge

Certification:
Participation

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

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

Preparation:
Bring a training module you want to facilitate

Certification:
Participation

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

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

Preparation:
Bring an open investigation case with related documents ready

Certification:
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

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

Preparation:
None

Certification:
Certification of participation and closing deviation

Key Features

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

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

Preparation:
Green Belt certificate, complex improvement project, laptop with Minitab

Certification:
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

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

Preparation:
Laptop with Minitab

Certification:
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