Training

The sessions below are designed to be highly interactive and include presentations, group discussions, activities, case studies and real world examples to enhance the learning experience.  We have also developed a range of simulations which provide hands on experience of Lean techniques.  Participants are expected to undertake improvement projects in their organisations concurrently with the training so the learnings can be applied immediately.

Note – training can be tailored to your requirements in both topics and delivery (in-house or public couses). See Events for dates of public courses.  Contact us for more details.

Day 1
Who should attend
From leaders / managers through to front line staff

Why you should attend
The ability to improve the processes you work with is a key skill to be mastered by all people in your organisation. This training day gives you an overview of the latest principles and tools for process improvement.

What you will learn

  • Overview of Lean & Six Sigma evolution and principles
  • What a Lean process looks like
  • The impact of variation on process output
  • Overview of Lean and Six Sigma tools
  • How to implement continuous improvement
  • Application to different areas of the business
  • Tips and traps for a successful implementation

More information

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Day 2
Who should attend
From leaders / managers through to front line staff

Why you should attend
Experience first hand the benefits of implementing lean improvements to a simulated process. This training day contains four rounds of a simulated process, interspersed with training on lean principles and tools.

What you will learn

  • The difference between “Flow” vs “Batch” production
  • The difference between “Pull” vs “Push” production
  • The meaning of takt time
  • The impact of standardised work, 5S, error proofing  & visual management on production
  • The impact of relayout and line balancing on production

More information

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Day 3
Who should attend
Leaders, managers and change agents

Why you should attend
Leadership is key to the successful implementation of process improvement. This training day covers the different approach of Lean leaders from traditional leadership styles and how to get acceptance within your organisation of the Lean transformation.

What you will learn

  • Changed mindset needed for Lean leaders
  • Policy deployment using the A3 process
  • How to get employee involvement in problem solving and process improvement
  • How to implement continuous improvement
  • How to tackle resistance to change
  • How to engage engage stakeholders
  • Managing change within the organisation
  • How to perform an Lean assessment
  • Application of Lean to different areas of the business
  • Important tips & traps based on experience

More information

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Day 4
Who should attend
From leaders / managers through to front line staff

Why you should attend
VSM is used to develop an action plan to focus and prioritise your process improvement efforts. By taking an end-to-end process view and applying Lean principles and tools.

What you will learn

  • How to facilitate a VSM workshop
  • How to draw a current state that identifies major problems
  • How to design a future state map that addresses these problems
  • How to prioritise actions and develop an implementation plan
  • Ownership of the value streams

More information

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Day 5
Who should attend
From leaders / managers through to front line staff

Why you should attend
Whilst the approach to VSM is similar to that for manufacturing above, this training day is specifically designed for service and office processes.

What you will learn

  • How to facilitate a VSM workshop
  • How to draw a current state that identifies major problems
  • How to design a future state map that addresses these problems
  • How to prioritise actions and develop an implementation plan
  • Ownership of the value streams

More information

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Day 6
Who should attend
Leaders, managers and change agents

Why you should attend
Process improvement is a “team sport”. To be successful, you need buy in from the people working in the process as well as the many stakeholders (customers, business, support, suppliers etc). This training day focuses on the facilitation skills needed to get the best out of the team and gain acceptance from the stakeholders.

What you will learn

  • Why process improvement is a “team sport”
  • Who should be on the team
  • Team effectiveness and decision making
  • The Lean approach to coaching/mentoring
  • What facilitation skills are needed
  • How to run a successful workshop
  • How to lead change

More information

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Day 7
Who should attend
From leaders / managers through to front line staff

Why you should attend
The Lean foundations covered on this day of training add stability and control to the processes and form the basis for future process improvement. Many organisations make the mistake of adopting the more sophisticated tools before the basic disciplines are in place.

What you will learn

  • 7 wastes and how to eliminate them
  • Basic problem solving (Plan Do Check Adjust)
  • How to implement error proofing
  • The benefit of standardised work and how to manage it
  • How to implement 5S (workplace organisation)
  • How to implement a visual workplace
  • Measuring performance

More information

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Day 8
Who should attend
From leaders / managers through to front line staff

Why you should attend
Rapid improvement events are intensive team-based improvement projects targeted at a specific area. These generally have a short time frame (one week) and yield significant productivity and quality improvements. Rapid improvement events are a great way to teach front line staff the Lean principles and tools as they learn by doing.

What you will learn

  • What is in a rapid improvement event
  • Why they are effective
  • How to select an area for rapid improvement event
  • Lean tools to use in a rapid improvement event
  • How to run a rapid improvement event
  • Case studies

More information

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Day 9
Who should attend
From leaders / managers through to front line staff

Why you should attend
How do you create a level flow of value added work through your processes that responds to the demand (or pull) of the customer? This training day covers the Lean tools needed to implement flow, pull and leveling.

What you will learn

  • Flow vs batch processing
  • Creating continuous flow
  • Lean layout and cell design
  • Theory of Constraints
  • Kanban pull systems
  • Leveling using heijunka systems

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Day 10
Who should attend
From leaders / managers through to front line staff

Why you should attend
Most processes rely on equipment and there is an increasing level of automation as technology improves. This training day focuses on how to get the best from existing equipment by measuring performance and addressing weaknesses.

What you will learn

  • Measuring equipment performance – OEE
  • Total Productive Maintenance
  • Quick changeover
  • Theory of constraints
  • Error proofing

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Day 11
Who should attend
Black belts and green belts

Why you should attend
Six Sigma is a data driven problem solving methodology used to solve the more difficult process problems. It uses the roadmap of Define, Measure, Analyze, Improve and Control (DMAIC). This training day focuses on the Define phase with the key deliverables of defining and scoping the project, engaging stakeholders and mobilizing the project team.

What you will learn

  • Defining a Six Sigma project
  • Preparing a charter & SIPOCR
  • Selecting the team
  • Voice of the customer
  • Engaging key stakeholders

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Day 12
Who should attend
Black belts and green belts

Why you should attend
This training day focuses on how to identify potential root causes of the problem, one of the key deliverables of the Measure phase.

What you will learn

  • Process mapping
  • 5 whys
  • Fishbone diagrams
  • Cause & effect matrix
  • Failure Modes & Effects Analysis (FMEA)

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Day 13
Who should attend
Black belts and green belts

Why you should attend
This training day focuses on how to determine baseline performance, validate the measurement systems and collect data on potential key root causes – key deliverables of the Measure phase.

What you will learn

  • Introduction to Minitab statistical software
  • Selecting performance measures
  • Data collection
  • Measurement system analysis
  • Determining baseline performance
  • Control charts
  • Capability analysis

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Day 14
Who should attend
Black belts and green belts

Why you should attend
An understanding of the variation in process inputs and outputs is important in determining root causes. The analysis of process data graphically is the first step and the focus of this training day.

What you will learn

  • Descriptive statistics
  • Graphical analysis
  • Multi-vari analysis
  • Normal vs non normal data

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Day 15
Who should attend
Black belts and green belts

Why you should attend
Statistical analysis extends your understanding of the strength of relationships between process inputs and outputs and quantifies the risks of drawing conclusions through sampling. This training day covers an introduction to the use of statistics and tests for differences in means and variance.

What you will learn

  • Inferential statistics
  • Hypothesis testing
  • Tests for means
  • Tests for variance

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Day 16
Who should attend
Black belts and green belts

Why you should attend
This training day builds on the previous day, extending the statistical analysis to data that does not follow a “normal” distribution and to differences in proportions. The relationship between continuous variables is examined using correlation & regression.

What you will learn

  • Testing for non-normal data
  • Test of proportions
  • Correlation & regression

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Day 17
Who should attend
Black belts and green belts

Why you should attend
Design of experiment (DOE) is one of the most powerful statistical tools used in process improvement. This training day uses a “Catapult team challenge” to teach how to design and run a DOE and the benefits of this approach.

What you will learn

  • Full factorial experiments
  • Fractional factorial experiments
  • Response optimization
  • Key tips and traps

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Day 18
Who should attend
Black belts and green belts

Why you should attend
Once you have validated the root causes in the Analyze phase, solutions are developed to control the root causes, thus controlling the output of the process. This training day covers how to select sustainable solutions and develop an implementation plan.

What you will learn

  • Solution identification & selection
  • Error proofing
  • Implementation planning
  • Stakeholder buy in

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Day 19
Who should attend
Black belts and green belts

Why you should attend
The Control phase is a critical element in producing sustainable gains. This training day focuses on how to validate and quantify the improvement and how to implement a control system to support and sustain the changes.

What you will learn

  • Verification of improvements
  • Process control systems (PCS) & supporting documentation
  • Standardised work & visual control
  • Control charts

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Day 20
Who should attend
Black belts and green belts

Why you should attend
This training day consolidates the learning of the Six Sigma DMAIC process by doing an integration exercise and reviewing case studies. An assessment with one-on-one coaching is provided to correct any gaps in knowledge.

What you will learn

  • Integration exercise
  • Case studies
  • Assessment

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