Managing the Change to Lean Manufacturing

Aim:

This course is designed to enable the senior management to successfully implement a Lean Manufacturing culture in their organisation. It is suitable for those either already involved with, or seriously considering being involved with lean manufacturing, regardless of previous knowledge or experience. The course will cover the basics for those unaccustomed to lean, and even for those who have experience with some of the techniques, the course as a whole will tie together all of these techniques and concepts to form an overall lean strategy.

It is well understood that for a Lean Manufacturing programme to be successful in an organisation, the top management and a critical mass of the workforce need to be involved. It is strongly recommended therefore that a cross functional senior management team undertake this course. In order to realise the benefits identified during this course it is highly recommended that you also undertake an educational programme involving the supervisors and shop floor workers.

The course encourages the management team to identify areas of their organisation, such as problem areas or ones that would especially benefit from a Lean Manufacturing intervention and develop a lean strategy, tailoring the available lean techniques to suit you organisation, its products, people, customers and market environment.

Qualification:

On successful completion of this course the candidate will be awarded a nationally recognised qualification endorsed by the Institute of Leadership and Management (ILM).

The course takes place over four days and is divided into four steps:

Step One - Project Scoping

This step comprises:

• Lean Manufacturing Overview
• Making Lean Fit your Market and Product Portfolio
• Strategic Analysis
• Establishing KPI's
• Organisational Change Drivers and Barriers
• Organisational Roll-Down Template

The outcome of this step is:

An established change management strategy.

Step Two - Assessment

This step comprises:

• Climate Survey
• Lean Assessment
• Centre-Out Method
• Process Mapping
• Value Adding Audit
• Takt Time Analysis
• Downtime Analysis
• Project Action Plan

The outcome of this step is:

A clear rationale to deliver substantial performance improvement against agreed action plan.

Step Three - Implementation

This step comprises:

• Change Management Training
• Project Management
• Improvement Teams
• Critical Path Analysis
• Value Stream Mapping
• Set Up Reduction
• 5S
• Failure Mode Effect Analysis
• Waste Analysis
• Kobayashi's 20 Keys

The outcome of this step is:

Tools and techniques to deliver step change to lean manufacturing.

Step Four - Evaluation

This step comprises:

• Steering Group
• Motivation and Change
• Objective Leaders
• Change Teams
• Change Monitoring - Plan versus Actual
• The Way Forward

The outcome for this step is:

To ensure structured progress towards programme goals.