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.
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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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: 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: 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: 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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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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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 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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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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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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By: Rob Ptacek and Jaideep Motwani (Ph.D)
Note: Currently out of stock. Orders placed today will ship within 2 weeks! Pursuing Perfect Service is a comprehensive and detailed set of instructions on how to implement Lean and Six Sigma tools and concepts in a variety of environments. It will provide the solid foundation upon which Lean Sigma tools can be applied in any service organization. Service providers are continually processing daily requests and must know how to identify client needs and expectations, how to best satisfy their needs, and how to do it at the lowest possible cost. This book is a step-by-step implementation guide for continuous improvement while creating a solid foundation upon which to build a service excellence culture. Pursuing Perfect Service also provides insights and examples on how Information Technology can be used to improve data and information flow to enhance the overall client experience, while ensuring organizational profitability. -
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By: Vlado Baban, Joe Buys, and Don Tapping
iLean's content will provide actual case studies, application examples, and working macros that have proven successful in improving information flow in all types of environments. iLean was arranged in a format that should provide you with enough detailed guidance (step-by-step instructions) to apply a similar-type Lean practice to your work process. Starting with Chapter 3, each chapter begins with a section titled Is this you? which was specifically designed to assist you in determining if that chapter has immediate relevancy to your current work challenges. Subsequently, it is suggested that a formal standard improvement methodology, Six Sigma's Design-Measure-Analyze-Improve-Control (D-M-A-I-C), Edward Deming's Plan-Do-Check-Act (PDCA) or some other similar methodology be used if a formal structure is required and/or more statistical analysis needs is required. However, many of the concepts and tools presented throughout this book can be implemented by an individual worker and, therefore, will not require a formal process (other than good project management skills). Microsoft s Office suite of products of Word, Excel, and Outlook, as well as Open Source applications of vTiger, Google Docs, and Huddle, are referenced throughout this book to provide an overall understanding of how Lean can be used to move information faster and more accurately than ever before. In doing so, you will be able to reduce inter-office dependencies, delays, and errors that may be present in your current business processes. -
By: Jayant Twewn (PhD), Todd Sperl, Rob Ptacek, and Deborah Salimi (PhD)
We are pleased to present Kaizen Demystified, perfectly timed for today s ever-changing and ever-demanding business environment requiring improved processes. Whether your industry is manufacturing, healthcare, financial, education, armed forces, services, government, or the construction industry, or, you are a manager, supervisor, team leader, or a front-line worker, this book will provide new insights and ideas for managing and facilitating continuous improvement and problem solving projects (i.e., Kaizen Events). Kaizen Demystified provides a simple and practical approach detailing five distinct methods on how Lean (and Six Sigma) tools and concepts can quickly and efficiently be applied and managed to solve business problems and improve processes. The five types of Kaizen Events detailed in this book are the: (1) Standard 5 Day Kaizen Event, also referred to as a Kaizen Blitz or Rapid Improvement Event, (2) Rolling Kaizen Event, (3) Web Based Kaizen Event, (4) Today's Kaizen Event, and (5) Wiki (or Quick) Kaizen Event. Each type will be thoroughly explained to demystify what it may mean for you. Kaizen Event Leadership is thoroughly explored in a separate chapter/section that relates to all types of Kaizen Events. It provides a listing of the common issues facing the leader of a Kaizen Event as well as suggested how-to leadership skills to address those issues. This is one of the most important aspects of leading any type of Kaizen Event. -
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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). -
By: Rob Ptacek, Mark Coats, Col. (Retired, US Army), Todd PtacekToday's Lean Leader is designed for use as a quick and convenient reference, or as a training guide to improve your effectiveness in leading, supervising, and coaching employees. It provides valuable insight into the How To's of leadership and supervision. Today's Lean Leader can be used in a variety of ways, some of which are: (1)The guide is valuable for the new or veteran leader - supervisor (2) Remarkably, the guide in the hands of the workforce makes the task of leading and supervising all the easier when everyone is on the same page on these basic principles. -
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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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By: Rob Ptacek, Todd Sperl, Jayant Trewn, PhD This book bridges the gap between a highly quantitative analysis of a process that requires extensive training (i.e., Six Sigma certification) and a more simplified approach that can be used and understood by the masses (i.e., Lean thinking). The goal of this book is to make the methods and tools of Lean and Six Sigma accessible to more people and provide a common sense or “practical” approach to problem solving and continuous improvement. This book is intended to be used by Sigma Belt Levels, Lean Senseis (i.e., teachers), Continuous Improvement Specialists, front-line managers, and supervisors of departments and work groups, and improvement team members in their efforts to improve all types of administrative processes while reducing waste and variations, and engaging employees. The Lean Six Sigma tools and concepts are presented relative to the A3 road map to provide a definitive how-to guide to problem solving and continuous improvement (Kaizen) initiatives. -
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The 5S for the Office User's Guide provides an organization with the forms, worksheets, and checklists necessary to ensure a 5S project is well-planned from the start - as well as ensuring the program is sustained over time. This how-to guide should be used as it is titled - as a "Guide". The information contained in this workbook should supplement, support, and enhance, etc. current materials that an organization may currently be using. Throughout The 5S for the Office User’s Guide there will be various quotations, performance points, references to PC file storage (the IT case study in the appendix) etc. to further invoke the overall need to do 5S in all types of administrative settings. As organizations automate more administrative functions (i.e., becoming more paperless) then there must exist that same type of organization and standardization for a physical file system as well as the computer file system. It is the focus of this User’s Guide to have the 5S principles apply to both the physical desktop (paperwork, desk layout, drawer organization, etc.) and the PC desktop (folders, files, emails, shortcuts, etc.). No workbook or guide can take the place of a person’s enthusiasm and passion to improve. However, what this guide can do is provide a good, solid foundation on what is required to effectively implement 5S in administrative settings while also spearheading efforts to bring those principles to the PC. -
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By: Roger Kremer and Tom Fabrizio The Lean Primer will allow you to train the organization to understand how critical the implementation of Lean principles and processes are to your short and long term success. It will provide the various reasons why an organization must go Lean, as well as detailing what Lean is. Lean will be explained in the terms of Stabilize, Flow, and Sustain with reference to the following topics of lean vision, waste, value stream mapping, 5S, takt time, buffer and safety stock, continuous flow, standard work, quick changeover, kanban, visual controls, mistake-proofing, leveling, paced withdrawal, visual production control, runners, TPM, and kaizen. Each of these tools will also be explained with digital photos from world-class shops from across the US that shared their best practices. -
A flexible template to make accurate current and future state drawings for your value stream maps.
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By: Rob Ptacek, Todd Sperl, and Jayant Trewn (PhD) The Practical Lean Six Sigma Pocket Guide is designed as a convenient, quick reference, and, most importantly, a step-by-step implementation guide. You can put your finger on any tool within a matter of seconds! Find the right tool for the right initiative by using the: - Navigate the Prepare - Define - Measure - Analyze - Improve - Control right side book tabs. - Complete the A3 Project Report as you learn and apply the various tools on the project by:- Go to the tab in the book that corresponds to the D-M-A-I-C Phase you are working on.
- Read about the tools for that phase of your project.
- Apply the appropriate tools.
- Complete the relevant section of the A3 Project Report.
- Repeat 1 - 4 as you navigate through the phases and complete your project.
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First of its kind! The Simply Lean Pocket Guide is the integration of Lean and the PDCA methodology. The interactive Tinker Town case study allows you to take problem solving with a Lean twist to your next performance level. The most basic premise of Lean is to simply and effectively problem solve. The Simply Lean Pocket Guide is a step-by-step approach to the implementation of process improvements using the PDCA model along with a Lean twist. If you are just beginning to adopt Lean or Six Sigma as a business improvement model, whether you are in the healthcare, financial services, construction, armed services, manufacturing, government, logistics, service, or construction industry, the first thing that should be acknowledged is that the solution to the problem (or improvement target that is to be reached) will be found in the intellect of the people who are working the process. Therefore, as a trainer, consultant (internal or external), or departmental head, the focus to improve a situation would be to “somehow” work with that group (and their intellect) and find a solution. However, that “somehow” is not always easy to attain and will require some guidance along the way. -
First of its kind! The Simply Lean Pocket Guide is the integration of Lean and the PDCA methodology. The interactive Tinker Town case study allows you to take problem solving with a Lean twist to your next performance level. The most basic premise of Lean is to simply and effectively problem solve. The Simply Lean Pocket Guide is a step-by-step approach to the implementation of process improvements using the PDCA model along with a Lean twist. If you are just beginning to adopt Lean or Six Sigma as a business improvement model, whether you are in the healthcare, financial services, construction, armed services, manufacturing, government, logistics, service, or construction industry, the first thing that should be acknowledged is that the solution to the problem (or improvement target that is to be reached) will be found in the intellect of the people who are working the process. Therefore, as a trainer, consultant (internal or external), or departmental head, the focus to improve a situation would be to “somehow” work with that group (and their intellect) and find a solution. However, that “somehow” is not always easy to attain and will require some guidance along the way. Simply Lean will provide that guidance ensuring root causes and wastes are eliminated in creating a Leaner, problem-free process.