This is a programme that combines…
- Developing a range of ‘hard skills’ based on key Lean Manufacturing methodologies that the Leaders would need in their roles, with….
- Developing the ‘soft skills’ of Leadership that the team leaders would require to most effectively implement the techniques taught in (i.).
We continually emphasise the intertwining nature of these 2 elements: Changing one of these elements will have repercussions on the other and vice versa.
In outline the subjects covered in this programme include :
1. The Manager’s role
- The role of the Leader in any Lean Initative.
- Emphasising Safety management as an integral part of any LEAN initiative.
- The importance of the right management structure in Lean initiatives.
2. Quantifying the benefits
- Using O.E.E. to focus Lean initiative cost benefits.
- Developing SMART objectives for Safety and Workplace Standards.
3. Organising the team
- Team-working in a Lean context.
- Prioritising and delegating tasks identified in a Lean action plan.
- Running effective Lean project meetings.
4. Leadership behaviours
- The appropriate Leadership style for Lean initiatives.
- Using the appropriate behaviour traits when encountering resistance.
- Handling the conflicts that can arise when implementing Lean methods.
5. Methods and training
- The importance of definitive procedures in a Lean context.
- Developing the appropriate training to support a Lean project.
- Effective Communication methods in a Lean environment.
- Absence control and Disciplinary procedures in a Lean environment.
The details of each module within the Lean Leader training programme is outlined below :
These modules are generally, to be delivered on a 1 session per month basis, allowing the attendees to undertake some project work based around the themes taught in-between the sessions.
The various units can be removed/modified according to the specific customer’s requirements.
Additionally, all of the improvement techniques taught are based on addressing specific business issues relevant to the business (e.g. Layout optimisation, Machine throughput issues, Quality complaints, Absence management, Downtime etc.) so that their relevance can be clearly illustrated.
A lot of the course involves specific training exercises undertaken on the shop floor.
Lean Leadership Development Programme Details
Module 1 : 1 day
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THEME | TRAINING HEADLINES | OBJECTIVES/KEY OUTCOMES |
Theme 1.
The Leader’s responsibilities with regard to health and safety. |
Safety management as the one non-contentious factor we can use for driving improvement initiatives: the W.I.F.M. (What’s in it for me!) factor! | The key outcome of this phase of the programme will be to both highlight the link between Safety and Performance management and to encourage the team leaders to use these concepts to come up with their own prioritised improvement plan.
As part of this process each attendee will be asked to carry out a safety audit of their own area using a simple template which can later be shared with their team. As such, the sessions will be a combination of training and practical exercises focusing on target areas. |
Theme 2.
The leader’s responsibility regarding World Class Manufacturing methodologies: with particular emphasis on workplace organisation. In this initial session we get the Team Leaders to take a ‘helicopter view ‘ of the Team Leader jobs so that they adopt a more holistic appreciation of the key role that Leaders play within the organisation. Just as for the safety audit, the team leaders will be asked to undertake a CAN-DO audit of their own area: and develop an appropriate prioritised action plan. |
Elements we investigate include…
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The key outcome of this phase is to get the Leaders to develop a prioritised action plan and make measurable and visible changes to the performance of the target areas.
Lean concepts to be trained in these sessions… 1. Asset care systems. 2. Area layout and ownership. 3. Leaking Pipe Waste Model. 4. Runners, Visitors and Strangers. 5. Optimal workplace layout 6. Shadow-boards and tool racks. 7. Organised storage systems. 8. Organising for Improved Safety. 9. Kanban systems for material control. 10. Visual Management systems. 11. Hot-spot boards. 12. POKA YOKE mistake proofing. |
Module 2 : 1 day | ||
THEME | TRAINING HEADLINES | OBJECTIVES/KEY OUTCOMES |
Theme 3.
The Leader’s responsibility to develop objectives and review performance with the team.
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Elements we investigate include…
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The key outcome of this training is that the Leaders need to understand that targets and their attainment is the life-blood of operational excellence. |
Theme 4 :
The Leader’s responsibility to develop their teams.
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Specific issues covered :
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The key outcome of this training is that the Leaders understand the human and motivational implications inherent in sharing and devolving responsibilities like this, and continually ask…’How can I enhance my role as a leader by using these techniques?’ |
Module 3 : 1 day | ||
THEME | TRAINING HEADLINES | OBJECTIVES/KEY OUTCOMES |
Theme 5 :
The Basics of Modern Maintenance practice (T.P.M.). Maximising throughput capacity by improving machine uptime is one of the most cost-effective philosophies of Lean manufacturing. |
Subjects reviewed include :
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Initially we get the attendees to ask some basic questions…
The key outcome of this training is to provide the Leaders with a an understanding that there exists a range of simple but very powerful tools for getting the best out of their equipment and realising the cost savings identified above. |
Module 4 : 1 day | ||
THEME | TRAINING HEADLINES | OBJECTIVES/KEY OUTCOMES |
Theme 6. :
The leader’s responsibility to Communicate effectively.
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Specific issues covered :
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The objective of this module is to give the Leaders the skills to communicate the techniques they have been taught in the earlier sessions.
Without the ability to effectively communicate these techniques, the message is lost! The key outcome of this training is to provide the Leaders with a range of Communication skills: and that they understand the rationale why some techniques are more appropriate to deploy than others, depending on the particular situation. |
Module 5 : 1 day
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THEME | TRAINING HEADLINES | OBJECTIVES/KEY OUTCOMES |
Theme 7 :
How to Lead Pit-stopping (S.M.E.D.) initiatives: What role does the Leader have? The key theme of this session is that Service is highly dependent on the effectiveness of Machine changeovers. This is where Leaders have a critical role to play in continually emphasising the importance of changeover discipline. |
Elements we investigate include…
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We emphasise the following…
The key outcome of this training is that the Leaders feel capable and confident to run (with help) their own Pitstopping (SMED) project. |
Module 6 : 1 day
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THEME | TRAINING HEADLINES | OBJECTIVES/KEY OUTCOMES |
Theme 8 :
An Introduction to Project management
All Leaders are required at some time to run projects. These may vary from the very simple to the extremely complex. Nevertheless some fundamental characteristics are true of all projects. However, how effectively these key points are managed can influence whether the outcome of the project is seen as a success or failure.
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Amongst the things we examine are….
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In this session we introduce some basic principles of Project management and get the participants to adopt a ‘helicopter view ‘of the project so that they have a better understanding of the Project Management PROCESS.
The key outcome of this training is that the Leaders feel capable and confident to run their own (albeit small-scale) project. |
Module 7 : 1 day | ||
THEME | TRAINING HEADLINES | OBJECTIVES/KEY OUTCOMES |
Theme 9 :
Waste Management Management of Waste and its control is one of the most Boring and Frustrating aspects of Operations Management, yet it can mean the difference between success and failure of the Enterprise!! Waste represents a significant share of lost profitability….. We must therefore conclude that…
…and therefore it HAS to be effectively managed. |
What we will cover….
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This course therefore addresses three elements critical to Waste management
Central to the course is the development of a Leaking Pipe Waste Model for the process under consideration. The key outcome of this phase will be a requirement for the attendees to develop a leaking pipe model for their area of responsibility and that they will be expected to lead their team in developing a Waste Management plan. |
Module 8 : 1 day | ||
THEME | TRAINING HEADLINES | OBJECTIVES/KEY OUTCOMES |
Theme 10 :
Value Stream Mapping Value Stream Mapping (VSM) is a tool to visually show all the actions (both value-added and non-valued-added) currently required to bring a product or service through to the customer. |
Step 1.
We map the supply chain to identify what happens and by whom this is done. We also try to identify the factors…
Step 2. For each of these steps we ask :
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This course deploys two simple but sophisticated techniques to analyse the value-streams :
Central to the course is the development of Value stream maps for the process under consideration. The key outcome of this phase will be a requirement for the attendees to develop Value-Stream maps for their area of responsibility and that they will be expected to lead their team in eliminating waste and reducing the non-value added ratio. |
Programme maximum : 8 days |