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Lean Workshops

LEAN TRAINING: Organizations that are applying Lean methodology to achieve the greatest improvements in speed, efficiency and profitability share a common characteristic. Each one fully utilizes the knowledge, skills and enthusiasm of people at all levels.

TAC's Lean Continuous Improvement Workshops are nationally recognized by "NIST" (National Institute of Standards and Technology) and are offered by certified instructors at ODU Business Gateway. Some are available on-site. These workshops can also be used to acquire CEU credits through Old Dominion University.

While the fundamentals of Lean are somewhat intuitive, many of the most successful components of a Lean toolbox have been developed over decades. Supplying the right training allows your organization to quickly learn these tools, how to apply them and realize the benefits of Lean.

Workshop Topics (Lean Toolbox)

  • Principles of Lean Manufacturing (with live simulation) - Through a mix of classroom and live simulation, participants learn to reduce cycle time up to 90%, improve on-time shipments up to 90%, reduce WIP up to 90%, improve quality up to 50%, and reduce floor space up to 75%. By the end of the session, participants will have transformed a traditional manufacturing or office environment into one focused on lean concepts.
  • Value-Stream Mapping for Lean and Six Sigma - To understand the power of this key process improvement tool, teams, made up of operators, supervisors, engineers, managers and executives, learn the techniques to gather information and create a map of their current-state value stream (information and product flow) for any business process. From this, Lean and Six Sigma concepts are applied to identify areas where waste in the value stream can be identified and a plan put in place to achieve an ideal future state.
  • 5S- Workplace Organization/Standardized Work / Visual Controls Workshop - This workshop utilizes the application of Sort, Set in Order, Shine, Standardize and Sustain to transform the workplace into a self-explaining, self-regulating, and self-improving work area where what is supposed to happen does happen on time, every time. . It is difficult to make a product or service flow through the operation if the processing steps are not properly sequenced, balanced and work methods are left up to the discretion of individual workers. This workshop introduces the concepts of standardized work and the importance of using visual controls. This will help teams define the best ways to currently perform an operation or processing step. The goal is to provide a sfe neat clean organized workplace. This workshop is ideal for plant managers, supervisors, office personnel, shop floor associates, and shop floor teams.
  • Cellular Flow Concepts/Pull/Kanban Systems- This workshop (with live simulation) takes attendees through the five-step process for designing and implementing work cells for any business processes that have a common sequence. The workshop teaches participants how to design and implement a visual, customer-driven pull material replenishment system as well. Attendees will learn how to implement repetitive pull systems, set up point-of-use material storage, interface with planning systems, and set lot sizes matched with customer demand versus using the outdated concept of economic order quantity.
  • Total Productive Maintenance - Total Productive Maintenance (TPM) means tapping into the "hidden capacity" in unreliable, and ineffective equipment. Learn how businesses have improved productivity, quality, customer service, and safety levels by reducing unplanned downtime by as much as 40% to 60% through this operator-based maintenance program.
  • Set-Up Reduction - This workshop (with live simulation) teaches the fundamental principles of set-up reduction based on the pioneering work of Dr. Shigeo Shingo, and his Single Minute Exchange of Die (SMED) system of set-up reduction. This workshop walks participants through the six-step, set-up reduction process.

"Train & Do" Improvement Projects
A "train & do" project uses the above lean workshops as an intro to multi-day activities where participants apply newly acquired knowledge to a real world process improvement activities at a client's facility. "Train & Do" events can focus around any of the preceding lean workshops.

Lean Six Sigma:

  • Lean Six Sigma Project Management - This service provides customized coaching, facilitating, consulting, and project management to assist your firm in facilitating, leading, executing and completing DMAIC based Lean Six Sigma projects. This project facilitation enables world-class quality and continual improvement to achieve the highest level of customer satisfaction.
  • Lean Six Sigma Black and Green Belt Certification - Development of internal capabilities to participate, and or lead Lean Six Sigma projects can help your business achieve strategically based initiatives. We offer certification through our Black Belt consultants and certified partners and verify capabilities through completion of actual Six Sigma projects. Participants will, upon completion of the program, be eligible to apply for certification.
  • DMAIC- Basic Statistical Process Control Techniques - Our team can provide your staff with the basic statistical analysis tools and techniques utilizing the DMAIC approach, to identify and define variability in processes, and develop the correct statistical tool to distinguish between common cause and special variation.