This series consists of three week-long workshops, completed over the course of
3 to 4 months. During the intervals, participants complete additional projects in
their workplaces and present their to their classmates.
The three courses are
the architecture for lean operations in this value stream mapping, analysis, and
design workshop. Discuss and apply detailed practical approaches for creating flow,
and explore a variety of pull systems.
In a progressive
series of hands-on simulations, apply the key tools that support a lean transformation:
5S workplace organization, workstation design, visual controls, standardized work,
setup reduction, and source quality. Explore the principles of pull systems for
production control & management.
the role of people in a lean system that is constantly learning and improving. Apply
a variety of team building and problem solving strategies including C4, Six Sigma,
and TRIZ, focusing on how to teach these methods to teams. Create a Daily Management
System for an effective workplace that teaches and engages team members, fostering
higher levels of performance and employee satisfaction.
This series is designed for change agents and leaders responsible for implementing
your transformation strategy. The series is intellectually rigorous but is tailored
to the audience to be appropriate for all team members. When completed as part of
the Strategic Transformation Partnership or Community Action Partnership, the series
is also physically rigorous, with long working days gathering data, analyzing processes,
building things, moving equipment, and a variety of other tasks. We have had CEOs,
Presidents, all levels of managers, supervisors, and team members from all departments
successfully complete this series.
Outcomes and Objectives
- Apply lean principles, techniques, tools, and practices
- Describe the principles, techniques, tools, and practices associated with lean
- Plan and execute a series of improvement projects in the workplace
- Gain the trust and engagement of team members in the workplace
- Help your company become more profitable
- See the value and the waste in your processes and systematically enhance the value
while eliminating waste, increasing your capacity and profitability
- Create work flow to improve delivery to your customers while ensuring perfect quality
- Teach and coach lean principles, techniques, tools, and practices to your coworkers
- Solve problems and drive improvements in your work processes
- Create a better place to work
- Apply basic team building approaches to develop more effective solutions to workplace
- Set boundaries and create repeatable processes through standardized work
- Describe basic leadership principles complementing a lean transformation
We believe the only way to achieve mastery in lean systems is through demonstrating
knowledge with -oriented projects completed in the workplace as part
of our overall education program. To earn the certificate, every candidate is required
to complete two transformation projects with support from their management. The
savings from these projects should pay for the education many times over.
We’ve developed three delivery options for these courses. The most effective tends
to be option 3, which we recommend.
Option 1: Public delivery.
Send your people to our public workshops in Kentucky. The price is $7,500 per person,
but with a larger group we discount that price by as much as 50%. This option allows
your people to interact with participants from other companies, making valuable
network connections for future idea sharing and learning.
Option 2: Conventional on-site delivery.
We will come to you to deliver the courses as designed. You provide the learning
environment (including room, audio visual equipment, office supplies, reproduction
of handout materials, meals, and refreshments) and send up to 28 people at a time
through the course series. The meeting room must be at least 10 meters wide by 12
meters deep (or 30’ x 36’). The price for the series is $75,000 plus expenses (instructor
travel, copies of handouts, onsite meals and refreshments, other supplies as needed).
We will schedule these courses at your convenience (within our own scheduling constraints).
With this option, we encourage you to coordinate the student projects to focus on
a particular value stream, so that the combined effect of many smaller projects
will have a significant impact for the company.
Option 3: Lean Systems Certification Boot Camp.
In this series, we focus on actual transformation and make the projects the vehicle
for learning. We will come and make an assessment of your facility, identifying
with you the key value stream and several projects substantial enough to achieve
our learning and cost savings objectives. You provide the learning environment again
(including room, audio visual equipment, office supplies, reproduction of handout
materials, meals, and refreshments.) Everyone also must have access to the gemba
(the workplace where we will complete the transformation projects).
During each week, the class (again, up to 28 people) will complete a series of cost-saving
projects that save you at least twice as much as the boot camp costs, . We will also invoice in a way that ensures the
savings hit the books before the bill does, making this partnership a great investment
for you, even in these troubled times. The price for this series is $120,000 plus
expenses. We’re averaging 12:1 returns with current dedicated clients in the . The boot camp often
requires additional instructors/facilitators.
The sequence of workshops follows
- Lean Systems Certification Boot Camp week 1 - Systems
- Assessment and Value Stream Mapping and Analysis workshop
- Lean Systems Certification Boot Camp week 2 - Processes
- Rapid Improvement/ activity
facilitated by ILS targeting the restructuring of key operations and processes identified
during the previous workshop.
- Lean Systems Certification Boot Camp week 3 - Kaizen
- Rapid Improvement/ activities
facilitated by ILS targeting detail work improvement and problem solving for processes
featured in Week 2 activities
Bootcamp weeks, like the others, are separated by 4 – 6 weeks each, where the participants
are required to complete any lingering action items from the workplace projects
completed during the facilitated week. ILS provides ongoing coaching to ensure progress.
For all of these options, we offer flexible invoicing to fit within your budget
better, ideally making this series cost neutral to your budget. We will also help
you submit grant proposals to state workforce development and economic development
agencies to further offset the cost of these programs. This still allows you to
bring people from your other facilities worldwide to participate.
For option 1 - Public Delivery, to secure seats in the public workshops,
we require registration and a nonrefundable advance deposit of $500 per person.
We can break out the billing so that you receive an invoice for each week, spread
out just like the workshops, rather than one lump sum for all three courses.
For option 2 - Conventional Onsite Delivery, no deposit is required,
but we will send you a contract that outlines our mutual obligations. You may choose
to pay lump sum in advance, or we can invoice by week, and if necessary issue multiple
invoices for each session spread out between weekly budget cycles.
For option 3 - Boot camp, we will work together to define the billing
sequence, so that it fits into your budget cycles and presents you with a clear,
cost-neutral option (the savings will hit the books as the invoices come due). This
option does require that we partner more closely to verify actual savings. It also
requires commitment from management to enforce the standards we will coach your
participants to put in place.
For smaller companies who may not be able to conduct a dedicated series, please
read about our, where 3 to 5 companies in a single geographic community
provide 3 to 8 people each to participate in the 3-week learning experience. Three
different companies work together to provide a host for each week. Participants
experience new learning in environments that may be significantly different from
their own, but still develop the skills to take back home. The objective of the
partnership is to provide the best possible lean systems education to organizations
at the lowest possible net cost.
We conduct this workshop for the public and onsite for individual companies. This
workshop requires no special facilities. The ideal meeting space is approximately
30’ x 30’. The boot camp option requires access for the entire group to the work