Lean Manufacturing Training

Organizations that are applying Lean Technology to achieve the greatest improvements in speed, efficiency and profitability share a common characteristic. Each one fully utilizes the knowledge, skills and enthusiasm of people at all levels.

R. Michael Donovan & Co. recognizes the essential role of lean education in developing a Lean Thinking organization. Our lean training is targeted to provide each contributor with the skills needed to support the success of a Lean initiative.

While the fundamentals of Lean are somewhat intuitive, many of the most successful components of a “Lean Toolbox” have been developed over decades. Supplying the right level of training allows your organization to quickly learn these tools and realize the benefits of Lean without expensive trial and error.

Lean manufacturing training from R. Michael Donovan & Co. is designed to provide the right set of Lean skills to people in every level in your organization. The training provides a common perspective and language that allows every individual to participate in continuous business improvement.

1. EXECUTIVE MANAGEMENT. (Typical Time: 8 hours) Knowledgeable and supportive leadership is an essential part of a successful Lean Thinking organization. Without this critical element, Lean efforts will either wither from a lack of resources or degenerate into “random acts of improvement” that have very limited impact on the bottom line. Our executive management training for business leaders covers:
   • Overview of Lean Technology
   • Magnitude of the opportunities
   • Using Lean for breakthrough improvement
   • Overview of the Lean Toolbox
   • Developing, managing and nurturing a Lean Thinking culture
   • Bringing the benefits to the bottom line
   • Hands-on examples to drive home Lean concepts
2. LEAN MASTERS (80 hours with additional Six Sigma training optional) The Lean Masters program is designed for organizations that want to develop a core group of highly capable, in-house experts. These individuals receive extensive training and one-on-one mentoring that allows them to tackle complex problems and deliver impressive, bottom line returns. As an option, Lean Masters can also receive Six Sigma training to industry standards for yellow, green or black belt certification. The topics covered include:
   • In-depth training on each item in the Lean Toolbox such as:
     • Value Stream Mapping
     • 5S
     • TPM
     • Set-up Reduction
     • Mistake Proofing
     • Level Scheduling
     • Visual Control
     • Kaizen
   • Organizing and managing Lean projects
   • Utilizing Line Design tools
   • Designing and mathematically sizing Kanban systems
   • Hands-on simulations including the total business impact of implementing pull systems
   • As part of Lean Masters Certification, candidates will be responsible for a Lean project that delivers a minimum financial return
   • Certified Lean Masters will have access to Lean Training materials to allow them to teach Lean within their organization
3. MIDDLE MANAGEMENT. (16 hours) This group plays a critical role in Lean since they most often have the direct responsibility for achieving results. At the same time, their functional areas (and even their own roles) will be affected as Lean technology eliminates non-value-added activities. As a result, it is essential that this group understands why improvement is required, their important role in the Lean organization, and how they can contribute to success. The topics covered in this training include:
4. LEAN IMPLEMENTATION TEAMS. (16 hours) Successful Lean Thinking organizations count on the capabilities of cross-functional teams. Often these teams will have the responsibility for a major project such as redesigning a product line, implementing a Kanban system, or introducing 5S. These teams require a more detailed understanding of Lean tools in order to accomplish their objectives. Their training includes:
5. OFFICE SUPPORT. (8 hours) This training is targeted for office employees who may not be a part of a Lean Implementation Team but still have a significant role in the success of a Lean initiative. The material provides them with the necessary understanding to allow them to support and contribute to a Lean project. The topics covered in this training are:
6. DIRECT LABOR (4 hours) Lean training for direct labor employees is designed to remove the mystery and apprehension regarding this new technology. The emphasis is that Lean results in a more effective business that is better able to compete in the world-wide markets. Many participants discover that Lean is a common-sense approach that makes their work easier and more interesting. Once again, hands-on examples are used to have everyone participate and to illustrate concepts.