Lean Event Support ...

Summary:

• Kaizen Breakthrough Event (3-5 days onsite)
• Two Day Lean Assessment
• 5S Lean Event (5 days onsite)
• Changeover Reduction Lean Event (5 days onsite)

Kaizen Breakthrough Events (3-5 days onsite)

During Kaizen Breakthrough Events, dedicated teams are led to rapidly deliver innovation and continuous improvement. The cross-functional team works together steadily for 3 to 10 days with 30-day follow-up. Actions link to lean objectives such as plant layout changes, cellular flow, setup reduction, quality improvement, pull system implementation, 5S - visual systems, standard work or methods improvements.

Kaizen events have a significant training component. Microsoft PowerPoint based training modules provide a lean thinking - kaizen overview, followed by specific techniques applicable to the current kaizen. Team members immediately apply what they learned to solve problems. Changes are dramatic. Analysis, brainstorming and targeted actions deliver operational performance breakthroughs.

Key Benefits

• Significant breakthrough change accomplished with measurable results
• Concentrated efforts by focused resources, during 3 to 10 day event, make it happen
• Cross-functional teamwork supports change to a culture of increased cooperation
• Lean capability development through training and practice supports continuous improvement
• Bottlenecks are relieved to help increase product throughput to increase revenue
• Improved quality and efficient standard processes yield consistent results
• Events show the organization that radical change is possible - so they embrace change

Activities

• Propose kaizen targets and sequence to accomplish value stream transformation
• Select bottleneck targets to increase throughput while reducing inventory and operating expense
• Prepare for kaizen breakthrough event: materials, videotapes, area, team and objectives
• Train team in lean and kaizen concepts and specific technologies applicable to the event
• Facilitate team to analyze process and brainstorm improvements
• Encourage data-driven approach and aggressive performance targets
• Direct and reinforce immediate implementation of significant changes in the workplace
• Define, assign and track activities to accomplish kaizen objectives
• Guide progress reviews and final report-out to reinforce team and involve organization
• Follow-up on thirty-day action plan and process standardization

Two Day Lean Assessment:

SSDSI offers a cost effective Lean Assessment visit in which Lean experts closely examine and evaluate your processes.

• We present management with specific examples of how our assistance in actually implementing the Lean concepts will impact the bottom-line in your organization.
• We develop specific recommendations and collaborate with stakeholders to create a course of action that will guarantee immediate and long-term "Bang for the Buck" gains.

What are we looking for during an assessment?

We teach your people how to find waste, appropriate ways of reducing it, and collaborate with them to make bottom-line improving changes.

5S Lean Event (5 days onsite)

This workshop is a key first-step (Sort, Store, Sweep, Standardize and Sustain and most important Safety) in any Lean implementation that builds program enthusiasm by having immediate and measurable impact on operations. 5S implementation workshop is a hands-on learning and implementation of 5S methods in a factory or office environment. Critical to the success of this workshop will be the participation of key process owners who possess accurate working knowledge of the current process identified in the scope of this session charter.

Benefits:

This workshop will provide opportunities to leverage the Lean skills and set direction for Lean activities

• High employee involvement
• Dramatic Impact
• Cultural Change
• Safety focused
• The precursor to:
  • Standard work
  • Quick changeover
  • Visual management
  • Process balancing
  • A full lean launch

• Waste Walk
• Red Tag
• Signage design and install
• ID & improve soil points
• Assign standard locations and procedures
• 5S score post-event
• Build, train and install control tools
• Out brief to leadership team

Changeover Reduction Lean Event (5 days onsite)

A ˝ day training session on the basic principles of lean and application of set-up reduction (SMED) to the operators and management team in the designated facility / department followed by a 4 day SMED Event in the selected area. The training will cover all aspects of SMED including real life examples of dramatically reducing the set-up, changeover, and start-up times of an operation. The SMED Event will then put the system into practice in the selected area, leading to major improvements in the set-up and changeover process in your facility. SSDSI's approach to SMED is not a license to spend lots of money, but rather uses a teamwork approach to focus on working with what you already have. The sequence of events is as follows:

• Identification of the Process/Area
• Selection of the SMED Team
• Training of the SMED Team
• Analyzing the current set-up/changeover process (i.e. videoing, spaghetti diagrams, time studies, etc.)
• Determining VA/NVA steps and internal vs. external steps
• Streamlining the process via standardization and new work area design/set-up process
• Implementation to the extent possible (Document action items if necessary for team follow-up)
• Solidify results and present to management team

• Substantial improvements in changeover times with minimal investment
• Additional capacity for future growth with minimal investment
• Improved productivity and throughput
• A more organized work place
• Standardized set-up and changeover procedures
• Bottom line results

Upcoming Events: