Lean Tools (for Hourly, Supervisors, and Technical Personnel)

Training For Manufacturing Companies

Lean Tools (For Hourly, Supervisors, and Technical Personnel) 2020-02-14T15:07:21-05:00

Lean Awareness

Standard course duration: 2 hours

This course presents a basic overview – the “what” and the “why”- of the lean initiative and defines roles of employees in its successful implementation. It provides information that everyone needs – the “how” in order to participate in a lean transformation. It shows how each and every employee – the “who” – can become a valued member of the company’s “lean” team. It also shows how everyone’s knowledge, support, and participation are essential to the success of this major company-wide effort.

Upon completion of this course participants will have learned the importance of lean transformation and its effect on company operations and their jobs. They will be able to determine how their job functions and responsibilities affect a lean initiative and how to become a valued member of the company’s “lean” team.

Dealing with Change

Standard course duration: 2 hours

Change is a constant in the business world; but for many employees it is difficult, disruptive to their work lives and even counterproductive.

The objective of this course is to provide participants with a different perspective – that of “change is opportunity”. By understanding the objectives or goals of change and the steps necessary to make the change, employees can better understand the positive impacts that will result from their new methods, roles, responsibilities, etc. Participants are challenged to look at the bigger picture in order to understand both the benefits of change and their role in successful change.

The course involves participants in a series of exercises designed to have them see both sides of personal experiences, turn what appear to be negative aspects of change into positives, and then apply that approach to their current situation. Participants also learn the value of measurement in both assuring action and tracking progress toward change goals.

Upon completion of the course, participants will have learned to see the positives associated with change and how to align themselves, their goals and their actions for success.

Identifying and Eliminating Waste (IACET CEU)

Standard course duration: 8-16 hours

Lean Manufacturing focuses on the identification of waste in its 7 deadly forms followed by investigating to determine root cause and then either eliminating or greatly reducing the waste. The prevention of waste involves the design and continuous improvement of the product delivery processes. This lean initiative is based on continuous performance improvement efforts of all employees. The purpose of this course is to provide an understanding of waste and its impact on company performance and then learn a practical approach to discover, eliminate, and prevent waste.

Upon completion of this course participants will be able to:

  • Explain why waste needs to be addressed
  • Define the basic concepts related to lean operations
  • Identify waste in their workplace
  • Distinguish root causes associated with waste

In order to obtain the .7 CEUs for this course, participants must complete the following:

  • 80% attendance of course sessions demonstrated via the sign-in sheet
  • 70% on the post-course assessment

Workplace Organization & 5S (IACET CEU)

Standard course duration: 8-24 hours

This course teaches participants five basic principles that form the foundation of the 5S System, a powerful front line tool and a common starting point for simplifying work processes, improving equipment maintenance, ensuring safety and product quality, and eliminating waste. Course topics begin with the pillars of 5S – Sort, Set in Order, Shine, Standardize and Sustain: Introduction to the 5 Pillars. Each is defined, requirements and implementation are discussed and then a practical workplace activity reinforces the concepts taught. As a sixth S, the course also teaches how to identify safety problems and their root causes in order to eliminate dangerous workplace conditions before accidents happen.

Upon completion of this course participants will have learned and experienced how apply the 5S pillars to their workplace and to foster an environment of continuous improvement on the shop floor.

In order to obtain the .7 CEUs for this course, participants must complete the following:

  • 80% attendance of course sessions demonstrated via the sign-in sheet
  • 70% on the post-course assessment

Quality at the Source

Standard course duration: 8-16 hours

The subject of quality management has undergone rapid and drastic change as a result of fierce competition in the marketplace and a heavy dependence on the quality of goods and services. This course teaches participants that quality is everybody’s responsibility and that everyone in an organization participates in determining the cost of quality. Course topics include: How to Think About Quality; What is Quality?; What is Cost of Quality?; Who is Responsible for Quality; Quality Planning: No More – No Less; Motivation and Self-control; Self-inspection.

Upon completion of this course participants will be able to determine how their work affects the quality of goods and services and the cost of quality. They will be able to apply learned skills in creating a cost efficient, self-controlled quality workplace.

Teamwork for Results

Standard course duration: 8 hours

This course teaches the advantages of a team-based approach and how to be a good team member. It includes the practical rules of teamwork and their application in participants’ daily work. It also teaches the team development stages that can be expected as teams form and learn to be effective. Participants learn the importance of communication to define and meet the specific work requirements of internal suppliers and internal customers and where to establish control points to assure that requirements are met, all as keys to achieving performance results.

Upon completion of this course participants will have an understanding what it takes to function as a high performance team and their role in their team(s). One of the most important purposes of this course is to help participants become more successful at achieving performance results in a team environment.

Lean 5M – Team-Based Problem Solving

Standard course duration: 8 hours

Lean 5M is a straightforward team-based method of Lean Manufacturing that addresses five components of a manufacturing process (Man, Machine, Material, Method, and Measurement). The 5M method is commonly used in identifying and eliminating waste in a broad range of work areas.

The course teaches participants the 5M method in a teamwork environment using various problem solving tools. Participants will learn 5M definitions, how 5M affects their work, how to develop a 5M root-cause (fishbone) diagram, and how to identify and eliminate waste by using the 5M diagram and effective problem solving tools, such as Brainstorming, Check Sheet, and 5-Whys. They will also learn how to work as a team and improve their work by understanding output requirements of their work to properly satisfy input requirements of their internal customers within the 5M methodology.

Upon completion of the course, participants will have learned the team-based problem-solving methodology of 5M and its application to their daily work.

Kaizen Workshop

Standard course duration: 8-24 hours

This course teaches a team-based approach to continuous improvement. It builds on the foundation blocks of teamwork and problem solving. It teaches the Japan-originated Kaizen approach as an effective way of introducing rapid change into an organization by utilizing the ideas and motivation of the people who do the work. It presents the philosophy of kaizen as the starting place for all lean improvements. This course takes participants through the critical steps in conducting an effective kaizen event-one that is well planned, well implemented, and well documented. It follows a “learn and do” approach.

Upon completion of this course participants will have applied continuous improvement and problem solving skills to an opportunity from their company’s operating environment. One of the most important purposes of this course is to help participants become more successful at problem solving in a team environment. Participants will be able to apply learned skills in their daily work and participate actively on cross-functional teams and kaizen events in selected areas.

Equipment Conscious Operators

Standard course duration: 8-16 hours

This course is based upon the foundation principles of Total Productive Maintenance (TPM). It explains the TPM activities that can be carried out by equipment operators themselves, working as a team with maintenance to maximize equipment productivity: autonomous maintenance; focused maintenance, and safety initiatives. These activities enlist the intelligence and skills of operators who are most familiar with production equipment and develop specific responsibilities in conjunction with the maintenance department. This course covers TPM basics such as the six big losses determining overall equipment effectiveness (OEE), causes of losses, and eliminating minor stoppages before they lead to major breakdowns.

Upon completion of this course participants will have learned how to improve equipment effectiveness and minimize maintenance costs. They will be able to apply learned principles in their work areas, working with maintenance toward shared goals.

Fundamentals of Workplace Safety

Standard course duration: 8-16 hours

An uncluttered, well organized, and understandable workplace is the foundation for safety. This course teaches a basic set of universal principles and activities that sustain safety conditions on the shop floor. It focuses on improving unsafe and hazardous conditions that exist before an accident occurs. It uses 5S techniques and OSHA guidelines to identify, implement, and standardize “best practices” for shop floor conditions.

This course covers the following safety areas:

  • Personal Protective Equipment
  • Lifting Techniques
  • First Aid and Bloodborne Pathogens
  • HazCom – the Right to Know
  • Fire Prevention
  • Lockout – Tagout
  • Confined Space
  • Electrical Safety
  • Machine Guarding
  • Chemical Spill Safety
  • Welding, Cutting and Brazing
  • Forklift Safety
  • Slips, Trips and Falls
  • Safe Material Handling

Upon completion of this course participants will be able to identify safety problems and their root causes through auditing tools and the safety checklist; select best practices for fixing, controlling, and preventing safety problems; and incorporate 5S safety techniques in your company’s safety training program.

Basic Skills

On the Job English for Non-English Speaking Employees

Standard course duration: 40 hours

This course is designed for people who need to speak better English related to their jobs in order to better understand and be understood in their workplace. This course teaches participants English words and their definitions according to participants’ job responsibilities.

Upon completion of this course participants will increase their ability in speaking English for specific terminology; better understand and communicate work related situations, better follow instructions given in English; as well as to increase their confidence and motivation.

Workplace Math

Standard course duration: 8 hours

An overview of basic math skills provides the foundation of arithmetic, mathematics and measurements used in common business and industry practices and their application to participants’ day-to-day work.

Participants will learn to:

Add, subtract, multiply, and divide whole numbers, fractions, and decimals. Measure lengths and distances.
Calculate areas, volumes, and weights.
Measure temperature in Fahrenheit and Centigrade, convert from one system to the other, and select the appropriate type of thermometer to be used at given temperatures.
Perform the basic arithmetic operations with signed numbers and signed terms, and transform and solve an equation.

Upon completion of this course participants will acquire the basic math skills to effectively perform their job functions. This course could be customized to accomplish company’s specific training requirements.

Fundamentals of Blueprint Reading

Standard course duration: 16 hours

Basic Blueprint Reading provides students with flexible courseware and instruction that enables them to understand the various types of blueprints, shop prints and schematics used in an industrial environment. Learning to read blueprints, trainees discover how to comprehend, and interpret the different types of standard symbols and abbreviations found on electrical construction drawings, schematics, and wiring diagrams.

Participants will learn to:

Define different types of scales used on drawings.
Identify the height, width, and length dimensions of a drawing.
Interpret the various symbols and notations used on drawings.
Draw multi-view sketches of simple objects that accurately show all the details of the objects.

Upon completion of this course participants will acquire the basic blueprint reading skills to effectively perform their job functions. This course could be customized to accomplish company’s specific training requirements.

 Good Manufacturing Practices

cGMPs – Manufacturing Employees

Standard course duration: 4 hours

This course is targeted to FDA-regulated industries such as pharmaceuticals, biotech, medical devices, cosmetics, food processing, and component suppliers to those industries. This general cGMPs training provides participants with the basic requirements for their conduct in a cGMPs manufacturing environment.  The course presents the elements of cGMPs as defined by the FDA, focused on prevention of adulterated or misbranded product. This course is an integral part of new employee orientation and should be repeated annually as a refresher.

The course objective is to create awareness of the regulatory requirements of a cGMPs manufacturing facility as they pertain to:

  • Employee Attire and Behavior
  • General Housekeeping
  • Product labeling and handling
  • Department Specific Housekeeping

Upon completion of this course, participants will understand the rationale for and the specific workplace requirements placed upon them and their conduct.

GMPs – Personal Care Product Industries

Standard course duration: 2 hours

This Personal Care Product manufacturing-specific cGMP training provides participants with the basic requirements for their conduct in a personal care product make, fill and pack environment where the primary objectives are product integrity and safety.

The course addresses two major risk areas as defined in the FDA’s cGMP Executive Summary, “deficient employee training” and “contamination of product”. This course is an integral part of new employee orientation and should be repeated annually as a refresher.

The course objective is to create awareness of the regulatory requirements of a personal care product manufacturing facility as they pertain to:

  • Employee Attire and Behavior
  • General Housekeeping
  • Raw Material or Component and Product Handling
  • General Record-Keeping

Upon completion of this course, participants will understand the rationale for and the specific workplace requirements placed upon them and their conduct.

GMPs – Food Industries

Standard course duration: 2 hours

This food-plant specific GMP training provides participants with an overview of GMP’s as they apply to food processing and packaging. It also defines the basic requirements for their conduct in a food manufacturing environment where the primary objective is food safety. The course addresses two major risk areas as defined in the FDA’s Food GMP Executive Summary, “deficient employee training and contamination of raw material”. This course is an integral part of new employee orientation and should be repeated annually as a refresher.

The course objective is to create awareness of the regulatory requirements of a food manufacturing facility as they pertain to:

  • Employee Attire and Behavior
  • General and Department Specific Housekeeping
  • Food and Food Container Handling
  • Buildings and Facilities
  • Equipment and Utensils

Upon completion of this course, participants will understand the rationale for and the specific workplace requirements placed upon them and their conduct.