The Lean Learning Center can help you with every aspect of your lean transformation from strategy to execution with our client services. We believe that there is no one recipe for lean and we won’t force fit practices that don’t fit your needs. There is, however, a Roadmap for Lean Transformation – a lay of the land that helps you understand where you are and the best way to get where you want to go. The Lean Learning Center will help you develop the right approach using the following implementation practices:
The Kaizen Workshop, or kaizen blitz as it is often called, is the most often used lean implementation tool. This vigorous, structured, team-based approach to drive waste out of any process defines the problem, selects the best cross-functional group of people and fixes the problem quickly using lean tools and techniques. It is highly effective in achieving significant measurable results in a very short time.
What distinguishes Lean Learning Center Kaizen Workshops from others? First, our passion for understanding your current state via process-mapping. Second, our focus on the ideal state to help you achieve breakthrough results – not just incremental improvement.
Lean Learning Laboratory®
The Lean Learning Laboratory® (L3) is a highly effective technique for changing the culture of an organization and realizing meaningful performance gains. It is regarded by lean implementation experts and those who have led organizations through Lean transformation as the single most powerful method for affecting sustained results.
L3 is a place — determined by process, sub-process, or geography — where small groups of people learn, practice and apply the rules, principles and tools of Lean at a faster pace, with greater frequency and at less risk than to entire business units. Once the L3 is successful, these small groups become catalysts for broader application throughout a business unit.
While L3 implementation always includes “Learn – Apply – Reflect” and demonstrate, the content and sequence of the basic training modules are customized for each organization. They are designed to accommodate an organization’s level of lean maturity and its specific strategic/tactical goals.
L3 topics include:
- Waste Walks
- Standardized Work
- Process Mapping
- Control Point Standardization
- Setup Reduction
- Practical Problem Solving
- Preventive Maintenance
- Visual Management
Management Lean Learning Laboratory®
Focusing on tools that go deeper than 5S and waste elimination, Management Lean Learning Laboratory® (ML3) methodology and training provides a structured set of tools for executives and managers to use on a daily basis throughout their Lean journey. These skills are critical in helping organizations pull everything together – rules, tools and principles – to ensure sustainable cultural and operational changes.
ML3 involves six basic levels of activities applied across 10 sessions. Module topics include:
- Creative Tension (current reality vs. the ideal state)
- Control Point Standardization
- Direct Observation of Work
- 5 Whys Problem-Solving
- Scientific Method A3s
- Visible PDCA (Plan, Do, Check, Act)
- Lean Coaching
Training is provided by a Lean Learning Center coach, who comes on-site for each session, which are typically 3-6 weeks apart. The skills are applied through a method of “Learn — Apply — Reflect”, which ensures internalization and sustainability of the practice.
Sometimes your objectives are too far-reaching for a simple kaizen to remedy. A Demonstration Project is an excellent method that follows the same fundamental structure of a kaizen, but tackles a much larger task. Whether you are planning a layout of an entire plant (greenfield or brownfield), launching a new service, or undertaking a merger, these major events can either bring you to the next level or halt you in your tracks. Executed effectively, Demonstration Projects can yield significant results.
Our lean coach can either be a project leader or can co-lead with your internal personnel. In either case, he or she will expertly guide your project teams through each step of our 9-Step Demonstration Project process, helping you build skill, change the culture and achieve big gains.
Lean Six Sigma
While some companies use Lean and Six Sigma separately, many have found greater success by integrating them into one comprehensive continuous improvement process. Integration entails working through many issues ranging from language to infrastructure. To ensure success, it must be done seamlessly with the ongoing running of your business.
The coaches of the Lean Learning Center have been through this integration many times and can help assess, plan and execute your Lean Six Sigma process. We can help you leverage many different activities toward this objective.
Our Lean Six Sigma Leadership workshop provides critical lessons and ideas to aid in your efforts. Assessment of your programs will help uncover crucial gaps before you begin your journey or once you are on your way. On-site training can be provided by lean-thinking Master Black Belts.
Customized Training and Development
Lean implementation approaches vary depending on the organization itself and the business conditions in which they find themselves. For example, 5S in a food processing organization looks very different than in a machine shop. Efficient work layout is very different in a hospital than it is in an auto parts manufacturer. Unstable conditions may require rapid improvement, while other scenarios call for a different approach. Some things work in certain cases and some don’t, making every next step even more critical.
All of these variables require experience in a wide range of industries and in varying business conditions. They also require the insight it takes to design and deliver an efficient and effective customized training and development program. Beyond our vast experience in many industries, what differentiates the Lean Learning Center is our one single mission – We will transfer our skills and knowledge to you and work ourselves toward disengagement.”