Participants will learn how to reduce manufacturing lead times by 80%, reduce work in progress up to 90%, reduce floor space up to 75%, and improve quality up to 90%. The class consists of a combination of classroom learning and live simulation.
Participants will learn the basic definitions of terms used in Lean Manufacturing, as well as 5S, Visual Controls, Facility Layout, Teams, Batch Size Reduction, Quality at the Source, POUS, and Pull Systems.
The students will learn about and understand how to identify the eight forms of waste. The techniques for eliminating waste and creating improvement performance will be taught and practiced through the hands-on simulation.
This process will result in
Participants will learn the basic definitions of terms used in Lean Manufacturing. They will learn how to reduce manufacturing lead times by 80%, reduce work in progress up to 90%, reduce floor space up to 75%, and improve quality up to 90%. The class consists of a combination of classroom learning and live simulation.
ISI will lead a company through:
The Lean and Green certification focuses on adapting Lean tools
broadly to environmental waste. Basic Lean tools (Value Stream Mapping, 5S, Eight Wastes, etc.) are introduced from the
perspective of the environment rather than the perspective of the customer, providing opportunities to reduce waste particularly in the area of overhead – that was previously inaccessible to Lean.
Participants will complete a real-world project over the course of training, and will meet individually with the instructor as a project coach. Participants are also expected to complete significant individual work on projects outside of class.
The Lean Waste Stream certification focuses Lean tools specifically on the solid waste dimension of operations. The forensic analysis of waste streams provides the entry point for identifying problems that can be addressed through basic Lean tools (Value Stream Mapping, 5S, Eight Wastes, etc.).
Participants complete a real-world project over the course of training, and will meet individually with the instructor as a project coach. Participants are also expected to complete significant individual work on projects outside of class.
Participants will learn the basic techniques of creating a Value Stream Map. The students will practice on a text-book exercise and then will map a real process within their own company. On day 2, the students will learn the methodologies for applying Lean tools to eliminate waste in the value stream. The workshop concludes with the students drawing a future state map and writing an action plan for achieving that future state.
Participants will learn the methodsof the 5S system and then apply what they have learned in a live situation in their own facility.
Participants will learn how to apply SMED and identify internal and external set-up operations. Participants will apply what they are learning to a machine in their company’s facility and will demonstrate the power of SMED to achieve a 30% improvement in changeover time in less than 2 days.
Participants will learn about cell design, work balance, single piece flow, standard work, point of use storage, visual controls and performance measurement. Application of cell design techniques will take place in a shop floor environment.
Participants will learn about pull signals. Kanban is a Japanese word that means “sign or signal” and is used interchangeably to denote any visual system for signaling production activity. This course includes instruction in design and application of the pull system method throughout the supply chain.
Participants will learn the terms and formulas connected with the TPM methodology. In addition, they will learn about the six types of waste that reduce equipment effectiveness. Participants will design the data collection methods and forms as they observe a machine. Also covered in this course are the formulas associated with the Operational Equipment Effectiveness calculation and information on how to use TPM as a tool for continuous improvement and employee empowerment.
Standard work is one of the basic building blocks of a Lean Transformation, but many people will not realize the potential benefits without a strong, cogent training method. Under the guidance of a seasoned facilitator, the participants will learn the Job Instruction four- step method as developed in the Training Within Industry methodology.
This is a perfect course for any company with an Engineering Department. The techniques can be applied to new designs, or to simplify current products.
Design for Manufacturability is a methodology that can dramatically reduce the part numbers and complexity of engineered parts, weldments and assemblies. Engineers and designers learn techniques to simplify the designs, making the parts easier to cut, weld and assemble: yet get better characteristics from the ﬁnished product. Material costs and labor hours savings are quickly realized. During the workshop, they will review assembly processes during two practical exercises, and create action item list for changes to designs.
Participants in Lean Implementer will learn to facilitate the Lean efforts at the process level of the company. These classes are hands-on experiences that equip participants with the tools necessary to become a successful Lean Leader.
Lean Green Belt covers the principles, tools and applications of 5S, VSM, Plant Layout, Training within Industry, Mistake Proofing, Kaizens, QCO, TPM, Cellular Flow, Pull Systems, Lean Performance Measures, Leadership Roles, Strategic Planning, Lean Program Deployment and cultural challenges. Engaging exercises to apply the skills in a structured environment incorporate data collection forms, videos and case studies. A test is administered on the final day.
Measurable Management ® equips front line leaders with skills and tools to engage their employees in continuous improvement activity within the company. This course is also a perfect complement to the company’s ongoing process improvement initiatives (e.g. Six Sigma, Lean) and will result in a boost to those efforts. Participants will learn a set of management skills and will practice how to apply those in their own work place.
In partnership with the University of Oklahoma Lean Institute, operating at the Norman campus, ISI offers Six-Sigma training, as well as 2 other unique Lean programs, Lean and Green Certification & Lean Waste Stream Certification, to further meet the needs of Oklahoma companies. The Six Sigma Certification can be held in an Open Enrollment format, in both OKC and Tulsa, or can be held on site for larger groups.
“Our entire customer service team, plus other key members, attended the Lean 101 class and held a value-stream mapping event with Industrial Solutions – ISI at our office to identify key processes in our Customer Service group that required improvement. As a result, our service has improved, our customers are happier, and our employees feel more empowered to identify and solve problems. A true win -win!”
Chief Growth Officer
Burrows Post & Frame Supply
Whatever level of lean consulting your company requires, Industrial Solutions can help. Broken down into Training, Facilitation, Lean Consulting and Development categories, ISI can provide the right service to get your company to the level you desire. From full business transformations to refresher classes, ISI has the resources and expertise to help you with lean consulting services.
“Our employee engagement is the best it’s ever been. Employees are gaining a level of satisfaction that makes them want to retire from the company although we are going through a down cycle. It’s not easy. I would recommend ISI to any company that wants to have lean thinkers.
We would never be where we are today without ISI.”
Since 1997, Industrial Solutions has been focused on serving companies with professional lean consulting, facilitation and training services in the application of Lean Thinking.
Our consultants are experts on a broad array of subjects, and can facilitate events on any of them, leading the process owners to achieve great gains.
Improvement events are a way to quickly transform the workspace and get employees engaged in the process.