Accelerated Route to Lean Manufacturing

Our full lean manufacturing programme is delivered face to face through a range of practical exercises and classroom-based sessions – each designed to transform your new knowledge into tangible, commercial improvements within your business.

What you’ll need

  • Access to a car or public transport to attend the face-to-face training
  • There are no minimum academic requirements for this course

How it works

  • Hands-on training, comprising presentations, discussions, group activities and interactive learning exercises
  • 10 days of 8-hour training (in addition to optional in-company activity) delivered over 10 weeks

Modules

Module 1: ARTL Introductions and Lean Thinking & Awareness

Educational Aims:

  • To provide an understanding of the guiding principles of lean manufacturing
  • To raise awareness of how companies become lean
  • To understand the structure of the Accelerated Route to Lean Manufacturing programme and how the forthcoming modules will equip the delegates to make changes in their own business.

Module 2: World Class Manufacturing – People and Process

Educational Aims:

  • To expose the link between Culture Change and a Continuous Improvement
  • To exhibit how culture can be successfully changed within a business
  • To demonstrate the requirements of a strong management team in achieving culture change.

Module 3: Value Stream Mapping 1 – The Current State

Educational Aims:

  • To be able to identify Value Streams
  • To understand why Value Stream Mapping is so important to successful Lean implementation
  • To understand why the seven wastes are present within organisations
  • To understand why “overproduction” is key to driving “un-lean” behaviours
  • To understand how to identify systemic waste and overproduction using current state mapping.

Module 4: Value Stream Mapping 2 – The Future State

Educational Aims:

  • To understand how to develop a Lean future state by optimising labour, leadtime and inventory
  • To understand how to link improvements to financial benefits
  • To understand how culture and behaviours can impact on a lean deployment programme.  

Module 5: Process Mapping and Kaizen Blitz Events

Educational Aims:    

  • To understand how and when to use two popular types of Process Mapping technique
  • To enable delegates to use Process Mapping techniques confidently in a variety of situations
  • To understand how Process Mapping differs from Value Stream Mapping (VSM)
  • To demonstrate the concept and practice of Process Mapping through case material
  • To introduce the concept of Kaizen workshops and blitz events together with a process and guidelines for approaching such events and sustaining any gains that are achieved
  • To outline the leadership styles typically encountered and to compare and contrast ‘Traditional’ management styles and leadership behaviours in fostering culture change.

Module 6: Problem Solving & Quality Tools

Educational Aims:

  • To appreciate what is meant by Lean principle five – Perfection
  • To develop an understanding of the tools and techniques of quality management
  • To understand how quality tools can be applied to resolve specific problems in support of lean developments
  • To understand why problem solving is a vital element of any Lean implementation
  • To demonstrate the use of problem solving methodology
  • To provide an introduction to Statistical Process Control (SPC).

Modules 7 & 8: Workplace Organisation and Equipment Effectiveness (Parts 1 & 2)

Educational Aims:

  • To understand the interactions 5S has on other aspects of a Lean organisation and how it enables Flow (and standardisation) to be achieved
  • To understand the calculation and benefits of applying Overall Equipment Effectiveness
  • To understand the mechanics of Total Productive Maintenance and recognise the need to apply it
  • To understand the process of changeover analysis and methods of reducing unnecessary/excessive downtime.

Module 9 Part 1: Build to Plan

Educational Aims:

  • To understand why we plan and schedule
  • To understand the difference between planning and scheduling
  • To understand why the achievement of the short-term schedule is so vital to lean applications.

Module 9 Part 2: Facilitation and Coaching

Educational Aims:

  • To understand how to facilitate CI activities
  • To understand the difference between coaching and mentoring
  • To understand how to coach people to achieve improved CI results

Module 10: Lean Implementation Considerations

Educational Aims:

  • To understand the need for a Lean implementation strategy
  • Appreciate the value and purpose of having a well thought through and communicated Philosophy
  • To recognise the Human Systems, the need to engage with our teams and the critical factors necessary for effective & sustainable Continuous Improvement and the transition to Operational Excellence
  • To identify and appreciate the qualities and attributes required of a Lean leader
  • Develop communication skills to enable respectful and progressive CI
  • Discuss processes and systems necessary to align the “top-to-bottom” resources in your organisation to achieve corporate aims & objectives.

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