Training

Implementing new approaches requires people who have the capability to succeed.

Aug 28-30, 2019

Hamburg

Statistics for APR/PQR

The expectations of health authorities have increased regarding the use of statistics in Annual Product Reviews/ Product Quality Reviews (APR / PQR). While historically it was enough to be “inside the spec limits”, now companies are expected to analyze and explain their product’s variation using various tools like distribution analysis, Control Charts and Ppk.

Details

Training Outcome
✓ Report writers apply statistical principles to assess product behavior and performance using solid, established tools.
✓ They become confident to apply the relevant, and only 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
  • Multiple Linear Regression

The three days can be done in one week or spread over 2-3 weeks.

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 APRs / PQRs

Duration:
3 days

Preparation:
Laptop with MINITAB, reading flash drives, process data must be sent to the trainer before the course (can be anonymized)

Capacity:
12 participants

Certification:
Certification of participating in training and about tools learned

Training Specialty
As participants bring their real cases, some “daily work” gets already done through the course reducing the time “away from office”. Together with increased confidence and speed of use, the three days of attending the training will result in multiple days saved per attendant and year.

Dates Aug 28-30, 2019

Location Hamburg

Price € 2,100

Sep-Oct, 2019

Hamburg

Green Belt

Improvement experts in process-oriented companies face specific challenges. Achieving performance improvements is often time consuming and creates change, while also being crucial for the future of the business: All processes influence a business’ success due to their impact on cost and quality in operations.

Details

Training Outcome

✓ Participants develop various skills to lead OPEX projects

1. Session (5 days)

Basics: Problem definition, Business Case, customer focus, techniques for visualization, Project Management, DMAIC, team facilitation, Lean metrics

Quick-Win techniques: Gemba-Analysis, Waste Walking, 5S

Data-based process analysis: Process Mapping, Measurement System Analysis, Root Cause Analysis, Process Stability, Process Capability

Project leadership: Risk management, implementation planning, change management

2. Session (5 days)

Team-based solution finding: Techniques for creativity and innovation, solution selection

Process improvement: Flow and Pull, Poka-Yoke

Sustainable implementation: Standard work, Shopfloor management, Kaizen, PDCA, Continuous Improvement

From project to daily business: Process-check-on-site, statistical process control, roles and responsibilities, project close-out

For whom:
Everyone with a passion to improve processes

Duration:
10 days (7 for transactional)

Preparation:
Laptop with MINITAB, reading flash drives, improvement project

Capacity:
12 participants

Certification:
Globally recognized certification, GB certification requires successfully completed GB project

Date:
Sep 2-6, Oct 7-11, 2019

Location:
Hamburg

Price:
€ 5.700,-

Sep-Nov, 2019

Hamburg

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. We certify these all-rounders as Lean Implementers.

Details

Training Outcome

✓ Experience with the key methods of Lean
✓ Successfully solved business challenge

1. Session (2 days)
Setting up projects and Kaizen workshops, facilitation skills and working with basic Lean tools like 5S, 7 Types of Waste and PDCA

Practical individual support (1 day)
Visit of your trainer and coach at your
site to work on your project and to adapt to the environment

2. Session (3 days)
Getting deeper into scoping and executing the projects right by learning about Lean Metrics, OEE, Gemba, Process Mapping, Value Stream Analysis, Standard Work and SMED

Practical individual support (1 day)
A practical workshop or Kaizen at your site with your trainer and coach

3. Session (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

Presentation of project story board and certification

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

Duration:
7 days of training, several days of project work Preparation: Bring a challenge or a project

Capacity:
3 or more participants Certification: Certification of successful project

Training Specialty
The biggest challenge with Lean is always a successful implementation. Therefore we focus on your specific situation in the training. Simulations, case studies and the challenge you bring to the training are real implementation expertise. This is also why we decided to not have you pass a written exam. It’s all about being able to apply it to your project.

Date:
Sep 26-27, 2019, Oct 22- 24, 2019, Nov 20-21, 2019

Location:
Hamburg

Price:
€ 7.200,-

Sep 11-12, 2019

Hamburg

Lean in Transactional Processes

Transactional processes are often rather “invisible”. As a result waste is more difficult to spot. It’s much harder to introduce transparency and to visualize progress or performance. And exactly this is why it’s even more important to introduce Lean into transactions. There’s a lot to win and here are the tools!

Details

Training Outcome

✓ A great overview on how to achieve success using Operational Excellence approaches
✓ Case studies showing how it works in different situations and for different challenges
✓ Participants experienced the mechanism of key techniques and gathered lots of inspiration

1.5-Days-Training

  • Implementing Flow and Pull in purely transactional processes
  • Transparency and Visual Management
  • Success techniques for all process improvement 
  • Performance management by boards
  • Budget Floor Management
  • Standard Work and 5S – Where and how?

 

For whom: For Operational Excellence experts, Belts, team leaders, leaders of services departments like IT, Purchasing, Supply Chain Management etc. 

Duration: 1.5 days

Preparation: None

Capacity: 4 or more participants

Certification: Participation

 

Training Specialty
It’s about understanding the philosophy and key mechanisms of the methods. At the same time the effects in small simulations as well as insights into many practical examples and case studies are experienced.

Date:
Sep 11-12, 2019

Location:
Hamburg

Price:
€ 1,100

Sep 13, 2019

Hamburg

Lean Leadership

Lean leaders increase efficiency and productivity through the way they lead, using feedback, coaching, regular meetings around boards and visualization (usually 10-20% annually). However, this requires changing the daily management style, behavior and habits of managers. This course prepares managers and executives for the requirements of effective Lean Leadership.

Details

Training Outcome

✓ Working effectively with boards in daily routines and improved leadership style

1-Day-Training

  • Basics on Lean and Continuous Improvement
  • Role of managers in a Lean environment
  • Experience performance management
  • Working with metrics and Visual Management
  • Managing by asking questions
  • Roleplay and receiving feedback
  • Driving successful board management

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

For whom: Managers and executives in Lean organizations

Duration: 1 day

Preparation: None

Capacity: 5-8 participants

Certification: Participation

Training Specialty
On the one hand, working in simulations within a safe environment helps to build an individual approach matching the personality for daily or weekly improvement routines. On the other hand, this change of perspective will have an impact on Leadership behavior in most situations.

Date:
Sep 13, 2019

Location:
Hamburg

Price:
€ 700

Oct 14-18, 2019

Hamburg

Master Black Belt

As leaders of OPEX Deployments and working directly with site management, Master Black Belts need both: a solid foundation in advanced methods as well as the ability to drive change on the highest level. This is a rare opportunity to hone one’s skills on this level.

Details

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

Duration:
5 days (4.5 days in class)

Preparation:

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

Capacity:
8 participants

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

Training Specialty
The final agenda is subject to change based on the current needs of this small group of experts. The program is encompassed with a rich evening program to allow for networking among and beyond the participants.

Date:
Oct 14-18, 2019

Location:

Hamburg

Price:
€ 4,000

Nov 5-6, 2019

Hamburg

Problem Solving

On the shopfloor most people understand a goal once they have started to work on achieving 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 where to rely more on systematic Problem Solving.

Details

Training Outcome

✓ Developed capabilities to solve real problems more quickly & more sustainably by involving relevant colleagues and using established tools

2 Days-Training

  • 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

The training can also be held on the shopfloor in your facility.

Tools & Methods in focus

  • Problem definition
  • DMAIC
  • PDCA
  • Fishbone (Ishikawa)
  • Detective method/ Is-Is Not
  • Pareto
  • 5W1H
  • Action Plan

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

Duration: 2 days

Preparation: Select real shopfloor problems to be tackled during the training

Capacity: 3 or more participants

Certification: Participation

Training Specialty

This training has the objectives to increase awareness for problems, build capabilities to drill down through symptoms to the real root cause and to empower to actively contribute to daily improvements.

Date:
Nov 5-6, 2019

Location:
Europe

Price:
€ 1,400

Nov-Dec, 2019

Hamburg

Black Belt Bridge

Green Belts have already experienced the power of Operational Excellence through Lean and Six Sigma during previous process improvement projects and training. They have seen the power of improving quality while simultaneously reducing lead times and production costs. Now it is time to strengthen their expertise and to increase the process improvement repertoire.

Details

Training Outcome

✓ Strengthened expertise and process improvement repertoire

1. Session (5 days)

Leadership: Team set-up, facilitation skills, go to Gemba, value creation through Lean, metrics to lead business and projects, change management, pull & flow

Data-based process analysis: Value Stream Mapping, measurement system analysis, data collection, process capability, advanced graphical tools, non-statistical Root Cause Analysis tools, advanced hypothesis testing, power and sample size

2. Session (5 days)

Leadership & Change: Lean leadership & performance review loops, Kaizen events, creativity and innovation techniques, Visual Management, managing implementation, standard work, drive business transformation

Data-based process control: Advanced regression techniques, Design of Experiments (DOE), Process monitoring, making change stick, implementing control plans

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

Duration:
10 days

Preparation:
Laptop with MINITAB, reading flash drives, Green Belt certificate, improvement project

Capacity:
9 participants

Certification:
Globally recognized certification, BB certification requires successfully completed BB-project

Training Specialty
The training will focus on deepening the use of tools from the Operational Excellence toolbox. Additionally, you will improve your facilitation and change management competencies, thereby becoming an improvement leader in your company.

Date:
Nov 11-15, 2019
Dec 2-6, 2019

Location:
Hamburg

Price:
€ 6,500

Nov 26-27, 2019

Hamburg

6 Genes Project Management

This course focuses on a pragmatic and successful approach to managing business projects. It is based on understanding the 6 core ‘genes’ of a project. It teaches that a successful business project requires a balance between the ‘command and control’ of planning and progress reporting to the ‘coaching and supporting’ of the team as they tackle new and unfamiliar challenges.

Details

Training Outcome
✓ Building and enhancing your skills to manage business projects using the 6 genes approach

2-Days-Training

Day 1

  • Introduction and Expectations
  • ‘What is a project?’
  • 6-Gene Model
  • Sponsor Gene
  • Leader Gene
  • Breakout session
  • Objective Gene
  • Methods Gene
  • Breakout session

Day 2

  • Budget Gene
  • Breakout session
  • Team Gene
  • Breakout session
  • Useful tools
  • Implementation

 

For whom: Everyone leading or about to lead a business project

Duration: 2 days

Preparation: Bring a project or project idea to the course

Capacity: 12 participants

Certification: Certificate in oConsulting trademarked 6 Genes Project Management Methodology

Training Specialty
The course is very interactive and the time spent on each topic is tailored to each audience. At the beginning of the course a participant survey is made and expectations are gathered. During the course, discussion and dialogue on current projects and past experiences is encouraged.

Dates Nov 26-27, 2019

Location Hamburg

Price € 1,400

Feb 20-21, 2020

Hamburg

Rapid Root Cause Investigation

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

Details

Training Outcome

✓ Investigators apply a proven, systematic and thorough method to identify the root causes of complicated deviations

2-Days-Training

Day 1

  • Introduction and Expectations
  • Overview of the Investigation
  • Lessons Learned from Deviations
  • rRCI Discovery Case
  • rRCI 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

You will also learn to effectively present your findings for decision making.

For whom:
Leaders of deviation / root cause investigations

Duration:
2 days

Preparation:
Bring an open investigation case with related documents ready

Capacity:
12 participants

Certification:
Certification of participating in training and about closed deviation possible

Training Specialty
Participants work on current and open cases from their site and are directly supported by experienced consultants. We highly recommend to combine this with additional coaching days over the following periods to close the investigations.

Date:
Feb 20-21, 2020

Location:
Hamburg

Price:
€ 1,400

Mar 24-25, 2020

Hamburg

Lean Train-the-Trainer

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 an enthusing learning experience. This training establishes the capabilities to get there.

Details

Training Outcome
✓ Developed capabilities to run excellent inhouse trainings on Lean topics

2-Days-Training
Teach-backs with lots of feedback are built throughout the day

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

Typical Lean Training Modules
We recommend to prepare one of these topics:

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

For whom: Future inhouse trainers

Duration: 2 days

Preparation: Bring a training module you want to facilitate 

Capacity: 3 – 5 participants

Certification: Participation

Training Specialty
You can’t learn to become a great trainer by theory alone. You have to train and receive qualified feedback. However, it’s also about a lot of interesting techniques helping you and providing structure. Therefore you get input first and then have the opportunity to practice. We will work in VERY small groups of 3-5 participants only.

Dates Mar 24-25, 2020

Location Hamburg

Price € 1,400

May 8, 2020

Hamburg

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.

Details

Training Outcome

✓ Participants being aware of Design Excellence and its implications for their current role whether as a line function, a product life cycle role or as a member of a development team
✓ Understanding the flow of the Design Excellence tools and how they work together, especially in the context of the Design Control process

1-Day-Training

  • Design Excellence Background
  • Design Excellence within a typical new product introduction process
  • Design Excellence simulation
  • Design Excellence tools like Requirements Identification and Prioritization, DEx 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

Duration: 1 day

Preparation: None

Capacity: 3 or more participants

Certification: Participation

 

Training Specialty
Use of a fun Lego simulation to illustrate Design Excellence concept and tools.

Date:
May 8, 2020

Location:
Hamburg

Price:
€ 700

May 22, 2020

Hamburg

Toyota Kata

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.

Details

Training Outcome

✓ Providing an idea of how Toyota Kata works and which benefit it will bring to your organization
✓ Getting first experience by applying Toyota Kata and inspiration for your leadership style

1-Day-Training
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 “Kata 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
  • Discussion: Where to implement Toyota Kata? Which cultures benefit from Toyota Kata?


For whom:
For leaders in all environments

Duration: 1 day

Preparation: Bring your own challenge

Capacity: 3 or more participants

Certification: Participation

Training Specialty

Toyota Kata is a very practical approach. And one day is the maximum to practice in a theoretical environment. We allow for a lot of experimenting, role plays and feedback, which will improve and broaden your leadership skills directly. To implement Toyota Kata the famous coach-trainer relationships and practicing within the real shopfloor environment are key success factors.

Date:
May 22, 2020

Location:
Hamburg

Price:
€ 700

upon request

on your site

Yellow Belt

Enable everyone to support a process improvement initiative by providing introductory training to a number of process experts, operators or raise awareness for Operational Excellence for project sponsors or managers. Yellow Belt trainings offer due to their short duration a good opportunity to reach many people and communicate basics together with organizational information.

Details

Training Outcome

✓ Yellow Belts are able to explain the idea of Operational Excellence and the Lean Six Sigma philosophy to colleagues and can contribute directly to essential conversations on processes and projects

1-Day-Training

  • Introduction and Expectations
  • Simulation Round 1
  • Introduction to OPEX
  • Problem Definition
  • High level process mapping
  • Voice-of-Customer & CTQ
  • Pareto Principle
  • Ishikawa Diagram (Fishbone)
  • 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 top- and middle-managers, sponsors, process owners and team members

Duration:
1 – 3 days

Preparation:
None

Capacity:
16 participants

Certification:
Globally recognized certification

Training Specialty

A key feature of our short trainings is to use a simulation to make the concepts & tools tangible. Our Dough-Moni Pizza delivery simulation for any audience, or the HR Lean Simulation specifically for transactional environments, are proven as a hands-on way to train what Lean Six Sigma is and increase the motivation for it in the organization.

Date:
On your site

Location:
Upon request

Price:
Upon request

Download a copy of our complete Training Catalogue for 2019 and 2020