A flexible template to make accurate current and future state drawings for your value stream maps.
The most significant factor allowing manufacturing to compete is the use of Lean manufacturing tools and concepts. Lean is based on the world-class practices of the Toyota Motor Corporation. Lean is comprised reducing waste, reducing costs increasing inventory turns, while increasing throughput, speed, while engaging the employee. The tools and concepts of Six Sigma should also be used for a comprehensive Lean Sigma approach to continuous improvement.
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This is a 10 minute virtual tour of Eaton- Aerospace Division’s Customer Service organization. It shows the before and after of the Order Entry Value Stream, along with testimonials on how it was done. The tools of 5S, value stream mapping, document tagging, standard work, runners, takt time, pitch, heijunka, kanbans, etc. are all shown working in this administrative setting. (Click on the photo for more information and to see a clip of the video.)
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The Lean Manufacturing Jeopardy Game is a highly-engaging game to reinforce Lean concepts presented throughout a training session or workshop. This activity is typically conducted at the end of a training session. Lean Jeopardy allows for the group to be energized with the information that had been presented, while at the same time having fun in a competitive manner. The Lean Manufacturing Jeopardy Game has four categories, What is it?, Why use it?, Where use it?, and Picture this? with 5 answers for each category. There is also an additional 100 answers provided in a Microsoft Word file from which you can cut and paste into the PowerPoint file for newer versions as you see fit. The new questions are referenced from The New Lean Pocket Guide (XL). -
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This set of forms has proven successful in many Fortune 500 companies. The key to any project or continuous improvement is effective communications and alignment to the strategic goals of the organization. Delivered as customizable Word documents. -
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A Waste Walk is an activity for project team members to further understand a process area that is being considered for improvement, asking questions, and then identifying the wastes on the current state value stream or process map. Using this customizable Waste Walk Audit form, the team members, along with their Lean training, can view the area with a fresh perspective as they identify process waste. Delivered as customizable Word document. -
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The Lean Office Assessment was created allowing a departmental work group or individual to continually assess their Lean or continuous improvement initiatives. The Lean Office Assessment is a customizable Microsoft Excel spreadsheet that will provide a baseline from which you can then improve your administrative processes. It also can assist in determining which Lean tools may be of value during a continuous improvement project. The Lean Office Assessment has 10 Lean building block categories that are further divided into 34 sub-categories that are individually scored. All categories are automatically linked to the Overview page which displays a Radar (or Spider) Chart of the total category scores. The score will assist you into allocating the appropriate resources in your Lean project. When conducting the Assessment the work group or individual must relate their database management procedures and Microsoft Office practices to the overall concepts and tools referenced. The 10 categories are: 5S, Quality, Physical Layout, Visual Controls, Standard Work, Continuous Flow, Pull Systems, Leveling, Continuous Improvement, and Training. -
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The 5S for the Office User's Guide Worksheets allow you to customize the tools, concepts, practices, and worksheets demonstrated in The 5S for the Office User's Guide. These 41 electronic worksheets will allow for more effective implementation of 5S practices in your administrative areas. Delivered as customizable Excel worksheets. -
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The Lean Desktop Application Assessment allows an individual or group to evaluate current information and data flow relative to Lean concepts and tools. The Assessment is a customizable Microsoft Excel spreadsheet that will serve as a baseline as improvements are made over time, The Lean Desktop Application Assessment should take 5 - 10 minutes for an individual to complete and 30 - 45 minutes for a work group to complete (fill out, not create). Subsequent analysis for the work group may require an additional 1 - 2 hours to plan their first Lean Desktop project from the results of the assessment. The Assessment has 10 main categories that are each linked to an Instruction Sheet that details that particular category as well as to the Overview Sheet (Radar Chart). The score will assist you into allocating the appropriate resources in your Lean Desktop project. The Assessment has 10 main categories of 5S, Quality, Document Management, Visual Controls, Standard Work, Continuous Flow, Email, Leveling, Continuous Improvement, and Digital Waste Training, as well as 34 sub-categories. -
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Work load balancing is the optimal distribution of work units throughout the value stream to maintain takt time or pitch. Also known as employee/staff balancing or line balancing, work load balancing assures that now one worker is doing too much or too little work. Work load balancing begins with analyzing the current state of how work relative to the value stream is allocated and ends with an even and fair distribution of work, ensuring that customer demand is met with a continuous flow mentality. The Employee Balance eTool will make this process easier by allowing you to enter the various process activities and cycle times, as well as automatically displaying them in bar graph form. This eTool is a fully customizable Microsoft Excel file. Everything is here and ready for you to get started! -
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The Simply Lean Kaizen Worksheets allow you to customize the tools, concepts, and practices demonstrated in The Simply Lean Pocket Guide. These 21 electronic worksheets will allow your Kaizen Events to be more effective in communicating the entire process. Delivered as customizable Excel worksheets. -
The chart summarizes where specific emerging technologies might be applicable and identifies the chapters from Today's Lean Leader where these technologies are specifically referenced. This is not completely comprehensive as emerging technologies change nearly daily. Leaders must be cognizant of emerging technologies and use them appropriately where they can improve their overall effectiveness, or the effectiveness of the team. -
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The Kaizen Demystified Worksheets allow you to customize the tools, concepts, practices, and worksheets demonstrated in the Kaizen Demystified book. These 46 electronic worksheets will allow for an effective and efficient application of engaging people in a Kaizen Event. Delivered as customizable Excel worksheets. -
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The Kaizen Worksheets include all the forms and checklists you need to conduct a Kaizen event. These are meant to support your internal kaizen event process. For more detail on how to conduct a kaizen event for your industry, please check The Lean Store.com for more workbooks detailing the process. Delivered as customizable Excel worksheets. -
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The Simply Lean Training Set is your 21st century solution to conveying the PLAN-DO-CHECK-ACT (PDCA) methodology with a Lean focus. This set is based on over 30 years of problem solving and Lean implementation. The Set allows an organization to teach the topics contained in The Simply Pocket Guide with numerous interactive case studies that allow the participants to practice using basic problem solving tools. The Set also conveys the most basic aspects of Lean through examples and digital photos. In this training set you will learn how to:- Use quality improvement tools through case study examples and activities
- Integrate Lean into any problem solving or Six Sigma project
- Conduct Kaizen Events
- Summarize the teachings through a Simply Lean Jeopardy game
- Conduct a simulation that conveys Lean and problem solving solutions
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By: Todd Sperl, Joe Buys, and Rob Ptacek The 5S Training Set allows you to lead a continuous improvement team in the training and the subsequent implementation of 5S. The presentation includes a brief overview of Lean, Six Sigma, and Lean Six Sigma, guidelines for each step, examples from successful 5S practices, as well as Sensei Tips from those who have done it. The worksheets that are referenced can be immediately customized in the accompanying Excel worksheet file. Notes are included throughout the presentation to assist in explaining the various slides. -
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By: Rob Ptacek and Jaideep Motwani (Ph.D.)
The Lean Six Sigma Training Set is your complete set of materials for conducting training on the tools and concepts of Lean and Six Sigma. With over 300+ PowerPoint slides, each tool is thoroughly explained with examples from a wide range of industries as well as administrative and desktop processes. Use this Training Set to customize and add/remove examples and photos as you deem appropriate. No training program that is purchased can be exactly what you want, therefore, it is expected this set be customized. Included in this Training Set are the following items: - 1 - Facilitator’s Guide that has the detailed Instructor Notes referencing The Lean Six Sigma Pocket Guide XL and Pursuing Perfect Service books - 1 - CD that contains the PowerPoint presentation, simulation, Jeopardy Game, and exercises -
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By: Edwin Garro and Luz Blanco Palma
El Curso de Entrenamiento de Manufactura Lean es un material de entrenamiento todo-incluido , que puede ser adaptado o personalizado de acuerdo con las necesidades de la empresa. Las herramientas Lean y conceptos son explicados en términos de los ejemplos reales de la planta, lo cual permite a los empleados entender mejor y luego aplicar las herramientas Lean. A través de esta guía del participante usted aprenderá:- Cómo aportar sus ideas a través de iniciativas Lean
- A entender cómo se utilizan las herramientas Lean al relacionarlas con ejemplos prácticos
- Cómo se aplican las herramientas Lean a través de su participación en una simulación 4) A mejorar sus destrezas técnicas
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By: Roger Kremer and Don Tapping
The Set allows you to teach the topics contained in the best selling The New Lean Pocket Guide (XL) with references throughout on the Note Pages of the Facilitator’s Guide. The Set has over 50 plant photos, 40 illustrations, as well as 6 different activities that will help teach the various tools comprised of Lean. -
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By: Jayant Trewn, PhD, Todd Sperl, Rob Ptacek, and Deborah Salimi, PhD The Kaizen Event Training package is your comprehensive set of materials to facilitate the training of those within your organization responsible for implementing continuous improvement projects (i.e., Kaizen Events). Five types of Kaizen Events will be detailed allowing teams to conduct full 5-day type events to conveying approaches on how individuals can contribute via kaizen in improving daily processes. The five types of Kaizen Events are: Standard 5 Day Kaizen Event, Rolling Kaizen Event, Web Based Kaizen Event, Today's Kaizen Event, and Wiki (or Quick) Kaizen Event. The materials are based on the best selling book, Kaizen Demystified which was written by authors/consultants with having conducted over 1,000 Kaizen Events! The training is for Black or Green Belts, Continuous Improvement Specialists, Lean Senseis, departmental supervisors and managers, work group or team leaders, etc. - basically, anyone that has someone reporting to them and is responsible for improving processes. Or, it can be used for Green Belt training or for those individuals who have little or no experience with Lean Six Sigma. -
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By: Joe Buys, Vlado Babon, and Don Tapping
The 5S Desktop (PC) Training Set allows you to apply the Lean tool of 5S to your electronic files and folders using Windows Explorer and Outlook. The Training Set is based off the best-selling The 5S Desktop (PC) Pocket Handbook with references throughout on the Note Pages of the Facilitator's Guide. You will learn the step-by-step procedures for organizing and standardizing all your electronic files through the Greybeck, Inc. case study. Also, through the 5S phases, flags, filters, and reminders will be discussed to ensure your emails are better organized and handled. 5S is a powerful tool to begin to improve office productivity in regards to data and information flow. -
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By: Luz Blanco Palma The New Lean Pocket Guide (en Espanól) La Nueva Lean de Bolsillo (Produccion Lean) Refuerze la transformación hacia los procesos esbeltos con La Nueva Guía de Bolsillo (Lean Producción). Este manual ha sido desarrollado tanto para directivos como para empleados, gráficamente explícito, sirve de referencia rápida sobre los procesos de manufacturación esbelta y está optimizado para reducir costos, optimizar la calidad, entregar los productos a tiempo y proveerlo con los conocimientos necesarios para seguir siendo ¡globalmente competitivo en el siglo 21! Esta guía está diseñada para usarla como referencia conveniente y rápida mientras se aprende a implementar la manufactura, tecnología y herramientas esbeltas. Este manual provee de una valiosa visión de los matices del proceso esbelto o lean. ¡Se tiene a mano cualquier aspecto del proceso esbelto en segundos! Y está definitivamente enfocado a las industrias manufactureras. El objetivo principal de esta La Nueva Guía de Bolsillo (Producción Lean) es informar sobre cómo las herramientas de procesos esbeltos pueden ser utilizadas para eliminar cargas y trabajo descartable. Cuanto mejor definido, analizado y resueltos los desperdicios, mejor sera la utilización de estas herramientas en la secuencia apropiada de implementación; por ende mejor será el recorrido del camino hacia la esbeltez globalizada. Indice de Materias - Matriz de Herramientas para Procesos Esbeltos, 5 Eses, Análisis de la Cantidad de Producto (CP) y del Desperdicios y Cargas Descartables, Existencias Acumuladas y de Reserva, Visual, Flujo Continuo, Heijunka (Nivelación de la Carga de Trabajo), Informes y Comunicaciones Esbeltas, Intercambio Rápido, Jidoka, Justo-A-Tiempo, Kanban (Sistema de Arrastre), Layout Celular: Forma de U, Manejo de Herramientas Perecederas, Manejo del la Cadena de Producción, Mantención del Total Productivo, Mapeo de la Cadena de Producción, Metodología para Resolución de Problemas, Métricas de Procesos Esbeltos, Nivelación de la Línea de Producción, Oficina Esbelta (Lean Office), Organigrama, Origen del Proceso Esbelto, Prueba de Errores, Responsable de la Producción, Retiro Pausado, Secuencia para la Implementación del Proceso Esbelto, Seis Sigma (Six Sigma),Talleres Kaizen, Tiempo Cíclico, Tiempo de Ejecución Taka, Tiempo de Retiro del Producto Empacado, Trabajo Estándar, Auditoría de Desperdicios y de Cargas, Glosario. -
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By: Don Tapping The New Lean Pocket Guide (Chinese Edition) has over 120 illustrations to visually convey the tools and concepts, along with detailed descriptions of all the Lean tools. This newer version of the best selling The Lean Pocket Guide also includes: a section on Lean Office and Six Sigma, 20+ digital photos demonstrating Lean in action, a Waste Audit, and a Glossary of Lean terms. The tools of 5S, value stream mapping, document tagging, continuous flow, standard work, visual control, takt time, pitch, runners, waste, plus numerous other Lean tools are thoroughly defined as well as guidelines provided for the implementation of each tool. This version has digital photos of Lean production best practices throughout! -
The Lean Pocket Handbook for Kaizen Events (Chinese Edition) is your personal (i.e., individual) Lean planner for the 21st century. We have found individuals that use this pocket handbook feel more part of the Kaizen team. They also continue to contribute improvement ideas well past the formal team Kaizen Event. That is what Lean is all about - making those small, incremental, improvements daily (i.e., hour-by-hour and minute-by-minute) by those closest to the process. Paperback - 3.75" x 5.5" - 96 pages -
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By: Don Tapping and John West
Who Hollered Fore? creates an awareness of the evils of variation – along with the realization of what that costs an organization in time and money. This book will assist in creating a common language and basic Lean theme throughout your organization. Through the story of John, Laura, and the Bartlett’s, as they participate in a charity golf event, the conversation about Lean and golf become intertwined. And finally they discover the secret to it all! About Who Hollered Fore? Who Hollered Fore? creates an awareness of the evils of variation – along with the realization of what that costs an organization in time and money. It also provides a common language and theme so everyone can understand its importance. This realization and subsequent action will dramatically improve an organization’s ability to improve the current process – thereby improving the bottom-line.