Lean Manufacturing Training

With a Lean Manufacturing System, your manufacturing company can reduce cycle time, improve on-time shipments, reduce materials wastes, improve quality, reduce costs and improve safety. Toyota pioneered the system now referred to as Lean Manufacturing -- and when's the last time you heard about layoffs at Toyota? Using an easy build-on-successes method, CITEC's Lean Manufacturing Analysts help your company through Phase One in your Lean Journey with a series of training programs, coupled with implementation advice. Find out more on our Lean Training page.


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Lean 101: Lean Principles Training

Lean 101: Lean Principles Training is the ideal starting point to learn basic lean concepts and principles. This one-day training session not only tells you about lean, it shows you through a series of in-class simulations.

You need to plan on attending Lean Principles Training if:
· You need a better understanding about what lean is and what it can do for your organization;
· Your company is toying with the idea of pursuing lean but aren't sure where to begin;
· You have already started down the lean path but existing employees could use a lean "recharge" or you've got new employees that need to climb on board;
· Or, your organization wants to apply for up to $50K of funding to implement productivity improvements (like Lean Manufacturing or Six Sigma) through the NYS Department of Labor's 17K Process Improvement Training.

Simply stated, lean is about creating value for your customers by getting rid of any waste in the process. Any activity that does not add value to the process is waste and obviously needs to be reduced or eliminated to improve your operation, while providing a higher quality product to your customer. Learning how to see waste, properly removing it and getting product to your customer in a more streamlined flow is critical to any successful lean implementation.

You'll learn about common Lean tools and techniques and discuss how to apply those in the best way possible from a Lean enterprise perspective. The simulation will give you hands-on proof of the power of one-piece flow instead of a batch system. (And, if you've been thinking that "it can't work here," you owe it to your company to attend this session to find out for sure!)

Workshop Objectives
· Introduce the concepts of Lean
· Illustrate the importance of creating organizational enablers at the beginning
· Build enthusiasm within your team

Agenda Topics
· Defining Lean
· Value Stream Improvement
· One Piece Flow - Simulation
· Leadership & Culture Change
· Lean - Beyond the Shop Floor

Who Should Attend
To truly be successful, Lean techniques and understanding the principles must involve top management, supervisors and those individuals on the shop floor (and in the office!) charged with implementing it. Also, if you are pursuing 17K funding for Lean or Six Sigma Process Improvement Training, individuals from the organization who can make decisions, or impact the decision-making process, must attend this course.

Ideally, attendees should be:
· Plant Managers
· Operational Leaders
· Value Stream Managers
· Human Resource Managers
· Financial Managers
· Trainers
· Supervisors

Your instructor
Jim Myers, CITEC's Lean Manufacturing Analyst
With 37 years of experience as a Lean Enterprise consultant, Jim transforms organizations into high performing, high commitment enterprises.

A sought after organization transformation professional, Jim is known for his extraordinary work ethic, his concentration on the client's opportunities, and his fast cycle, results-driven process. When there are tough situations, such as labor relations issues or acute management leadership problems, he is often called in to work on systemic solutions.

During the past three years, Jim has worked in a wide variety of businesses using Lean tools and the Lean system to help them achieve dramatic and lasting results, including large international companies in the US Defense and Aerospace industry, the food industry, healthcare, pharmaceuticals, paper, automobile components, as well as mid-sized to small companies in electric motors, fragrances, plastics, electrical components, printing industry, etc.

These seminars are not currently scheduled, but on-site training at your facility over multiple shifts is available and public sessions will be added based on interest. Contact us for details.

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Training Within Industry (TWI)
Giving Supervisors the Tools to Succeed

TWI consists of three standardized programs covering essential skills needed by all supervisors and team leaders, regardless of the industry: Skill in Instruction, Skill in Improving Methods, and Skill in Leading.

Each TWI program follows a proven four-step process: Preparation, Presentation, Application, and Testing. Supervisors are given the opportunity to learn and practice the process in a confidential, low-stress, and highly supportive environment. Each program is simple, straightforward and easy to implement. Class materials include pocket reference cards for daily use after the program has been completed.

Job Methods Training (JM)

Teaches supervisors how to improve the way jobs are done. The aim of the program is to help produce greater quantities of quality products in less time by making the best use of the people, machines, and materials now available. Supervisors are taught how to break down jobs into their constituent operations. They question details and develop new methods by eliminating, combining, and rearranging these details.

Job Instruction Training (JI)

Teaches supervisors how to quickly train employees to do the job correctly, safely, and conscientiously. The objective is to help supervisors develop a well-trained workforce resulting in less scrap and rework, fewer accidents, and less tool and equipment damage. Supervisors are taught how to effectively break down a job for instruction. The method emphasizes preparing the operator to learn, giving a proper demonstration, identifying the key points in the job, observing the operator perform trial runs, and tapering off coaching while continuing to follow up.

Job Relations Training (JR)

Teaches supervisors how to build positive employee relations, increase cooperation and motivation, and effectively resolve conflicts. JR emphasizes that people must be treated as individuals. Supervisors are given foundations for developing and maintaining good relations to prevent problems from arising. Principles include providing constructive feedback, giving credit when due, telling people in advance about changes that will affect them, making the best use of each person's ability and earning the employee's loyalty and cooperation. When problems do arise, it teaches supervisors how to get the facts, weigh them, make the decision, take action, and check results.

These seminars are not currently scheduled, but on-site training at your facility over multiple shifts is available and public sessions will be added based on interest. Contact us for details.

Universal Troubleshooting

The universal troubleshooting course is designed to help participants develop a consistent, effective process for troubleshooting any well-defined system. A well-defined system has a clearly defined state and behavior typically documented in an installation and/or user’s manual. This course is generic in nature and thus is not tied to any specific type of equipment or system. The focus will be on troubleshooting in a manufacturing environment.

Objectives:
Upon completion of this course we expect that the participants will be able to:
1. Apply the 10-step universal troubleshooting process.
2. Find all the root cause(s) quickly without backtracking.
3. Achieve greater consistency in troubleshooting.
4. Work calmly and efficiently in high-pressure situations.
5. Gather and sort through symptoms.
6. Optimize diagnostic tests*.
7. Develop a strategy to address intermittent symptoms.
8. Recognize and avoid incorrect assumptions when troubleshooting.

Deliverables:
CITEC uses The Universal Troubleshooting Process course developed by Steve Litt (troubleshooters.com). A three-ring binder will be provided to each participant with all the material presented in the slides. Class exercises will be used throughout to help the participants understand and apply the universal troubleshooting process. We will also provide time in each session for participants to discuss specific troubleshooting challenges they face. Participants who attend a minimum of 75% will be awarded a certificate of completion.
The course covers the following:
• Troubleshooting myths
• The 10-step troubleshooting process
• Intermittent vs. reproducible symptoms
• Motivation and how to maintain a productive troubleshooting attitude

Participation:
To ensure involvement of all attendees, this course has a maximum of 12 participants. All materials are provided.

*This course assumes that participants have access to and know how to use diagnostic test equipment.

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Lean White Belt
A Lean Certificate Program
You have the power to learn how to implement Lean improvement and create positive change for your organization.

This unique, in-depth 11 module program is designed in a proven, successful format of learn-implement-teach to develop your understanding of Lean productivity improvements, your use of the techniques at your facility and your ability to guide others at your company to realize real impacts.

The outstanding success of the recently completed LWB series is reflected by the companies interest in registering more of their employees for the next series and in the comments by participants.

"I'm very satisfied with the CITEC Lean White Belt Series experience. The content is highly relevant and invaluable to those in the manufacturing arena. The format and tempo of the course was digestible. The materials provided are priceless. The instructor is valid and generous, pulling from his vast anecdotal accounts of Lean implementation. In a short time, we have seen results of using the Lean tools. This matters."

Derrick M. (program manager for a
North Country composite manufacturer)

Taking over where single-day or week-long training leaves off, completion of this learn-implement-teach Lean White Belt program means you will be able to:

This intense Lean White Belt Program includes 22 topics covered in 11 full-day, highly interactive sessions held once each month with in-plant implementation and training required between classes (similar to Six Sigma Green Belt programs). Attendees learn about the improvement tools of Lean during classes that feature discussion, simulation and interaction. In the weeks between sessions, participants must complete and in-plant application of the tools learned and share their experiences with fellow students at the next session. CITEC staff is also available to provide coaching and in-plant support to better insure the success of White Belt students.

Jim Myers, Lean Sensei and CITEC's Lean Manufacturing Analyst is the lead facilitator for this program with support and mentoring provided by CITEC's Lean Manufacturing Team of experts.

To enable them to independently conduct Lean training and application with their own companies, each Lean White Belt candidate will receive a complete Trainers Manual for all of the programs covered; and a copy of all training CDs and videos.

Program Agenda/Schedule:
The training is held once a month for 11 consecutive months.

Topics covered include: Lean Principles, 8 Wastes; Value Stream Map - Current State; VSM - Future State; Lean Project Implementation; Hoshin Planning; 5S Workplace Organization (Parlor Factory); Visual Controls (Visual Factory); Physical Layout for Flow (Cell or Work Center); Standard Work (Individual Job, Cell or Work Center); 1-Piece Flow Cells; Cell Teams (Technical & Social System); Visual Pull (Kanbans & Supermarkets); Materials Presentation & Materials Handling; TPM (Total Productive Maintenance); SMED/Quick Changeover; Workforce Flexibility, Cross Training & Job Rotation; Level Production (Heijunka); Zero Waste Culture (Cell or Work Center); Zero-Defect Quality (Mistake Proof, Fail Safe); Urgency of Material Flow; Kaizen Events; and, Lean Leadership (Cell or Work Center).

Cost to attend:
While offered elsewhere with fewer topics for $15,000 per person, plus travel & expenses, CITEC is pleased to present a more in-depth program right here for companies of the North Country for $2925/person. (Contact us for pricing to have multiple attendees participate or to conduct this training at your facility for 12 or more participants.)

Price covers workbook binders with content material for all 22 topics, 19 videos on CDs, meals/refreshments, recognition awards (framed certificate and martial arts white belt) and ceremony.

Not included in the price, but strongly encouraged, is the purchase of Lean books from our instructor's recommended reading list to add to your company’s library for use by LWB participants. For a copy of the recommended reading list, contact us.

Registration:
The Lean White Belt certification program is offered as a series of public sessions based on interest, as well as on-site for companies with 12 or more attendees. For details, contact CITEC's Marketing Director Tricia Wilson by email or by calling 315.268.3778 x23. Don't miss this important opportunity for developing the Lean White Belt champions your company needs to realize real improvements. Through their successful completion of this program, you should expect your Lean White Belt champions to initiate changes that will result in a return on your training investment with the first year!

*Additional important program notes: