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Lean

it's not just for manufacturing anymore

The Lean Model

Lean establishes a systematic approach to eliminating waste (non-value-added activities) and creating an efficient flow throughout the company. Through lean, companies are able to maximize customer value with fewer resources. Benefits include reduced cycle and lead time, inventory, and work-in-process costs; increased capacity, productivity, profits, and customer and employee satisfaction; and improved safety record. Lean helps companies develop and implement a long-term plan to streamline operations with a focus on growth and innovation.

MTS provide resources, coaching, and training in a number of lean-related areas including value stream mapping, kaizen, 5S system, pull systems, quick changeover, setup reduction, total productive maintenance, lean office and lean certification. If you don't see a particular service listed, please ask.

 

Lean 101 - Introduction to the Principles of Lean Manufacturing

Lean 101 is a one-day, hands-on workshop where an overview and history of lean, lean tools and basic principles of Lean Manufacturing are presented in a fun, interactive event. The workshop uses a “learn and do” approach where attendees will use what they have learned to make changes to the simulated factory using a structured lean Kaizen event.  During the simulation exercises, attendees, as a member of the “production team”, apply lean concepts such as standardized work, visual signals, batch-size reduction, pull systems, quality at the source, and more. Plus they will experience firsthand how lean concepts improve quality, reduce cycle time, improve delivery performance, reduce WIP and enable the company to show a profit and gain a competitive edge in the marketplace.  Each simulation looks at metrics related to lead-time, production output, quality, inventory, revenue and profit. 

Attendees will leave this workshop with a good understanding of how lean concepts could enhance performance for most any type organization. Organizations new to lean or looking at implementing lean in their company would benefit from having their employees and key personnel attend. Lean 101 training would also benefit organizations that have been applying lean concepts, but may have some employees who have not been fully exposed to using lean tools. 

  

Lean Series

If Lean 101 is an introduction to Lean, the Lean series is one step beyond…a 201 if you will. The lean series is comprised of nine two-hour mini-classes that each focus on each of the following building blocks of Lean.

1. Value Stream Mapping 
2. 5S 
3. Standard Work 
4. Quick Change-over
5. Pull/Kanban Systems 
6. Total Productive Maintenance 
7. Cellular/Flow Manufacturing 
8. Problem Solving 
9. Teamwork

 

Lean Certification

Whether you have been on your lean journey for a while and need to get back to the basics, or just thinking about starting the journey and don’t know where to start, this workshop series is for you.

This is a multi-level program recognizing tactical, integrative, and strategic application of standard Lean principles. Designed by three organizations – the Society of Manufacturing Engineers (SME), the Association for Manufacturing Excellence (AME) and The Shingo Prize for Operational Excellence – this alliance established the standard for continuous improvement and lean practices. 

  • Provides the opportunity for significant lean training and development
  • Is an established Lean standard recognized world-wide
  • Develops internal Lean expertise to lead your continuous improvement effort
  • Knowledge + Experience = Lean Strength

The Lean Certification program helps manufacturers build internal capacity by providing their key staff with a working knowledge of the principles and practices of Lean. The training will be a combination of learning in the morning sessions and applying the tools in an afternoon session (8 hours total).  Many of the afternoon events will be hosted at participants companies to get a hands-on experience in a manufacturing environment. Each session will focus on a fundamental tool of lean, session 8 will be Lean Certificate of Knowledge Exam.

Included in the Lean Enterprise Certification Program:

  • Seven 8-hour training sessions and a 4-hour Certification Exam
  • Books / Study Guides
  • Homework sheets
  • Handouts from each session
  • Testing tips and methods
  • SME test for bronze lean certification (Certification requires test plus three documented projects)
The training series will consist of:

Lean 101 (session 1)
Value Stream Mapping (session 2)
5S CLASS – (session 3)
Standard Work – (session 4)
Setup Reduction & Total Productive Maintenance – (session 5)
Pull/Kanban Systems – (session 6)
Cellular/Flow Manufacturing – (session 6)
Problem Solving – (session 7)
Highly Effective Teams – (session 7)
Lean Certification Exam – (session 8)

 

Lean Manufacturing

Meet demand while increasing productivity and capacity. A lean enterprise produces more with existing resources by eliminating non value-added activities. Manufacturers are facing increased worldwide competition and the stakes are high. The winners in this competition work to eliminate overproduction caused by traditional scheduling systems and to only make what customers want when they want it.

Lean establishes a systematic approach to eliminating these wastes and creating flow throughout the whole company. It also helps you develop and implement a long-term plan to streamline your operations for success.

  • Reduce cycle time
  • Reduce inventory    
  • Reduce costs
  • Increase capacity
  • Improve lead times
  • Increase sales
  • Increase productivity
  • Improve quality
  • Increase profits
  • Increase employee satisfaction
  • Increase customer satisfaction

 

Lean Marketing

Achieve top line growth without breaking the bank. A lean marketing is a step by step system that grows sales and profits by identifying and eliminating areas of waste in the marketing/sales process. The system optimizes and leverages all current marketing assets/processes. It shortens the sales cycle - gets products/services to customers as fast as the customer wants. This approach to marketing can increase sales and profits, increase and speed up cash flow, all without having to spend any more money on traditional advertising/marketing strategies. 

  • Increase the number of prospects
  • Increase the conversion rate of prospects to customers
  • Increase the value or worth of each customer

 

Lean Office: Applying Lean to Office and Administration

Lean organizations produce greater value with higher quality in less time. In the beginning, Lean was only applied on the factory floor. But many organizations – even non-manufacturers – are discovering that Lean applied to the office can offer even greater improvements to an organization’s bottom line.

This class uses a variety of exercises, including a simulated office situation using iPads, to demonstrate Lean concepts and the quantifiable benefits you can achieve by applying Lean in your office. This class focuses on the unique application of Lean to an office where processes are not always visible. Using an interactive approach, students will use several tools to learn the best way to see a process, identify waste and how to determine the Lean tools to use to create a more effective administrative organization.

Lean Office helps companies with any type of administrative function to streamline information flow - the gathering, improving, movement and storage of information. Just like lean for the factory floor, Lean Office focuses on reducing total cycle time - in this case, the time between orders being placed and when payments are received. Typically 50% of cycle time is spent waiting for customer payment. Lean Office can reduce your cycle time by streamlining beyond the shop floor and improving customer and employee satisfaction in the process.

Implementing Lean in your administrative areas will help you:

  • Reduce paperwork process time up to 90%
  • Improve on-time performance up to 90%
  • Reduce work in process up to 90%
  • Reduce errors up to 50%
  • Reduce floor space up to 75%
  • Increase operational effectiveness
  • Provide better clarity to job roles and functions
  • Increase process flow
  • Improve productivity and profitability

 

This class will help you apply Lean effectively in an office environment. Students will learn:

  • the importance of focusing your activities on how they provide value to the customer
  • how to map processes to make waste visible and to determine where to make Lean changes
  • what are the wastes and how they can be minimized or eliminated
  • how to manage change as you implement Lean continuous improvement throughout the organization

 

Lean Product Development

Lean Product Development offers tools and methods to improve time to market and reduce the risk inherent in new product introduction. It also provides ways to reduce the waste in, and improve the results of, product development efforts.

The typical product engineer only does 1.7 hours of value added work in an 8 hour day. Lean Product Development gives you ways to reduce wasted time and improve the effectiveness of your product development process.

 

Lean Transformations

A true lean transformation requires engagement and understanding across the organization including leadership, middle management, and front-line workers.

Lean Transformation is a systematic approach to acquiring and applying a shared way of thinking within an organization. It does not start with a list of tools to change the way things are done. It starts with a change in the way everyone in a company thinks about what they do, how they do it and why it matters. It starts with an open mind and proceeds from there to permeate and change the whole business from the boardroom to the last link in the supply chain.

  • Improved cash flow
  • Higher profitability
  • Higher productivity
  • Increased capacity