Lean Toyota Visits 2016

Transcription

1 Toyota continues to offer their support to Ireland s efforts to improve competitiveness, capability and capacity through their Lean Management Centre in Deeside, North Wales. To date we have had over 1,500 people take the opportunity to visit the plant and to learn about and see Toyota in action, as a part of their effort to be better. In 2016 we are jointly planning a developed agenda of short courses in the plant in Deeside, delivered by active Toyota team members. The focused training sessions will allow people the chance to learn about specific tools and will also afford the opportunity to see how they are being used within Toyota.

2 Director Level Visit 2 Days When: Monday 14 th & Tuesday 15 th March 2016 Monday 28th & Tuesday 29th November 2016 Cost: 1250 per person (up to a max of 4 delegates per company) (+23% VAT Total ) dinner included on the first evening with the Toyota team. Management today is faced with the challenge of meeting market requirements with limited resources, often under very challenging timelines. Lean methods and practices are seen as being central to helping companies in Service, Manufacturing, Health Care, Pharma, Medical Devices, Food and Software sectors to address these challenges. Toyota is widely regarded as being at the forefront of Lean Process development. Enterprise Ireland has secured access to the Toyota Lean Management Centre, located at the Deeside Engine Plant, giving Irish managers gain access to true Toyo-ta thinking and practice. Enterprise Ireland is looking for expressions of interest to participate in a focused Director level visit to the facility. The visit is focused on senior managers, directors and board members to support the National effort to enhance positive competitiveness within Irish business. Duration The Mission is designed as a two day interaction with the Toyota team. Focused on seeing how the company develops and deploys strategy, manages their business as a management team, how they engage with and develop their people and learning about the Toyota Way and Production System. The Mission will blend sharing with "going to see", visiting the shop floor and the management areas of the operation. Experienced Toyota management team members will deliver the content during the Mission and are open to answering questions and sharing their experience and knowledge. Director, Senior Managers and Board Members. The Mission is planned to support the National effort to enhance the engagement of Lean within business to drive sustainable competitiveness. Which Sectors The Mission is open to and suitable for people from all sectors. The focus on processes, strategy deployment and management will support people from all sectors involved in a capability development journey.

3 Effective Line Management 1-day Workshop When: Monday 04 th April 2016 & Tuesday 05th April 2016 (6.30am start in plant) Cost: 450 (+23% VAT ) per person (up to a max of 4 delegates per company). It can be a very complex and difficult task to manage the resources of an organisation effectively. This can be made even more difficult for an organisation engaged in the pursuit of lean. The role of management and its leadership capability are essential to ensure that the tools of lean and the human resources are deployed in harmony with one another. Leaders must set and maintain the expectations that the employees are required to rise up to. They must provide the levels of support and direction necessary to engage and motivate people. Our leadership style is founded on the principles of Plan, Do, Check, Action (PDCA) and we have developed several leadership tools that enable us to constantly deliver the highest levels of operational performance. Our leaders firmly believe in the culture of the Toyota Way, they recognise it s not when they get the task done that counts, but more importantly how they get the task done! A leadership culture that operates with both short and long term perspective to continually drive our organisation forward. Workshop Our 1 day workshop provides delegates with an opportunity to study the leadership tools deployed in Toyota, experiencing what it s like to be a first line supervisor in a lean environment. They will understand the role and support provided by each level of management in ensuring high levels of operational performance are achieved on a daily basis through true teamwork. The level of personal commitment required from a leader. The need for Gemba and real shop floor observation The PDCA cycle Fact based decision making Visual management tools & techniques Management kamishibai The power of positive confirmation Effective use of Andon All Supervisors and Managers with leadership responsibility

4 Lean Management Intro 1-Day When: Monday 25 th April 2016 Cost: 450 (+23% VAT ) per person (up to a max of 4 delegates per company). Want to better your business? Do you want to become more competitive and efficient, boost staff morale and motivation, and reduce waste, cost and effort? Then start living the Lean Way! Not sure where to start or what it s all about? Have you enjoyed some success but are not sure of the next step? Are you struggling to embed the skills and engage the workforce? Are you not convinced that Lean would work for you? The answers to these questions and many more will be provided on our Lean Management Workshop! The Lean Management Workshop explores in detail the concepts of both the Toyota Production System (TPS) and The Toyota Way management behaviours. TPS is our approach to achieving high operational performance and is widely admired and copied throughout the world. The lean tools associated with TPS can be found in manufacturing and service providers alike. More recently hospitals, government offices and financial institutions are enjoying the benefits of TPS. However TPS cannot be totally successful in isolation, we have to have an organisational culture that supports, encourages and continuously improves TPS. This culture is embodied in the concepts of the Toyota Way, concepts that apply equally at all levels in the organisation. Ensuring a culture that truly believes its people are its most important asset! Toyota Philosophy & Basic Thinking A Customer driven focus Continuous improvement & 7 Wastes Shifting Sands or Solid ground Importance of Stability TPS Overview Production Planning & the Pull System Human Resources for a Lean Environment Role of Management Executive management, all managers & Lean transformation leaders

5 Effective Maintenance 1-Day When: Tuesday 26 th April 2016 Cost: 450 (+23% VAT ) per person (up to a max of 4 delegates per company). Stability is the foundation or bedrock of the Toyota Production System, without stable, reliable and repeatable processes it is difficult to implement standardised work and operate just in time. It is essential that the machines and equipment used within the process are reliable and capable for the purpose they are intended. To ensure the high levels of reliability demanded it is important that we deploy the correct approach to our machine maintenance activities. Our approach is firmly embedded in the principles of Total Productive Maintenance (TPM) and involves all levels of the organisation in a focussed programme of asset care. This approach ensures the total participation and development of every employee in delivering outstanding levels of machine availability leading to operational efficiency measures in excess of 95%. It is a dynamic system that is constantly evolving the maintenance requirements to truly meet the needs of the equipment and balance the cost of maintenance with the desire for high performance. Workshop Our 1 day effective maintenance workshop provides the delegate with a unique opportunity to study / benchmark our manufacturing maintenance strategy and its practical application. Delegates will understand our systematic approach and its link to TPS. They will also understand the key elements of the system and the visualisation tools and techniques utilised to drive for even higher levels of machine reliability performance. Who does maintenance and the role of the Maintenance Department. Proactive & reactive maintenance activities Our approach to condition based monitoring Developing the skills for good maintenance How to create ownership at the shop floor level Factors to consider for the ideal maintenance strategy Production and Maintenance Managers & Supervisors

6 Process Mapping 1-day workshop When: Monday 16 th & Tuesday 17 th May 2016 Cost: 450 (+23% VAT ) per person (up to a max of 4 delegates per company). Value stream mapping is a tool for visualising the flow of material and information within a process and quite often will be referred to as Material & Information Flow (M&I) within Toyota. If you can imagine your business as a time line that starts from the point when you get the order and ends at the point you collect the cash then what we are trying to do is reduce that timeline by eliminating non value added activities within it. M&I enables us to visualise the timeline and grasp the opportunities. It can be used to understand both the current state and as a tool to visualise the desired future state of any process. Utilised effectively M&I taps into the creativity and innovation of all employees and together with a culture of kaizen will lead to higher levels of process efficiency and labour utilisation. 1 Day Workshop Our 1 day workshop will provide delegates with the ability to study an existing process and create an M&I diagram. From this they will then be able to identify waste in the form of stagnation. With a clear image of the ultimate goal future state and the next step ideal situation they will be able to create an improvement plan and drive it s implementation. The purpose of value stream mapping How to study the process and recognise all points of stagnation Establish targets for future state conditions Develop and implement an improvement action plan All levels and areas within an organisation

7 Developing Standardised Work 1 Day When: Monday 20 th June 2016 Cost: 450 (+23% VAT ) per person (up to a max of 4 delegates per company). A Tool to ensure Safety, Quality & Efficiency in any process Standardisation and Kaizen form the platform that supports the Toyota Production System. Without clear standards it is impossible for people to judge if a situation is normal or abnormal. In this situation how can we ever be certain our actions are adding value to a process and not just creating more waste? Without a clear standard how can an employee be certain they are meeting the expectations of their supervisors? Standardised work is one of the tools of standardisation and creates the opportunity for Kaizen. It organises and defines process steps and human movements. This is important because when a process is disorganised there is no baseline for evaluation, improvements are unclear and difficult to monitor and true Kaizen is impossible! Standardised work is a tool that can be applied to any process where human interaction is present and when used correctly will lead to increased levels of motivation by creating employee process ownership and engaging them in continuous improvement activities! 1 Day Workshop Our 1 day workshop equips delegates with the skills required to create standardised work and recognise opportunity for Kaizen. Delegates will understand the importance of standardised work and its role in ensuring safety, quality and efficiency is built into their process. Delegates will also understand how, when standardised work is established, shop floor observation can be performed effectively and abnormality eliminated quickly! Correctly study the worksite and visualise the current state. Identify waste, value added and non value added activities. Redesign the worksite to ensure Safety, Quality and Productivity Create a Kaizen plan to eliminate waste. All levels up to and including Managers

8 Kaizen - 1 Day When: Tuesday 21 st June 2016 Cost: 450 (+23% VAT ) per person (up to a max of 4 delegates per company). Kaizen (continuous improvement) has long been recognised as one of the major tools of the Toyota Production System (TPS). Practicing Kaizen on a daily basis ensures that we constantly challenge to find a better way of working and therefore eliminate waste within our operations. For that reason TPS never stands still and constantly evolves to the next level. Kaizen is a process of making small improvements continuously and targets the elimination of waste and non value added activities. It is a process that engages, empowers and motivates the employees at all levels to strive for perfection. Tapping into the innovation and creativity of our people ensures we can make continuous improvement without the need for massive levels of investment expenditure. Of course when Kaizen and technical innovation are deployed together the benefits to an organisation are endless! 1 Day Workshop Our 1 day Kaizen workshop will equip the delegate with the skills to drive continuous improvement. It will enable them to clearly identify waste within a process clarifying the value and non value added activities. Delegates will also understand how to develop an action plan to improve from the current state situation. The 3M s The 7 wastes The prerequisites for successful kaizen The philosophy of Work Kaizen before Equipment Kaizen All levels up to supervisor and managers where appropriate

9 Residency When: Monday 19th - Friday 23rd September Cost: TBC

10 Practical Problem Solving - 2 Days When: Thursday 20 th & Friday 21 st October 2016 Where: TBC Cost: Stability is the bedrock of the Toyota Production System, without stable, reliable and repeatable processes it is difficult to implement standardised work. In order to eliminate sources of instability an organisation must be capable of solving problems. Many organisations often struggle with effective problem solving and find that the best they can achieve is to merely contain the existing problems by introducing more waste into the organisation. For example an unreliable machine will be managed by adding in more stock to protect supply to the customer or through the acquisition of a second machine to ensure throughput. Real problem solving countermeasures the root cause of an issue preventing it from reoccurring and in doing so creates stability with the least amount of waste. Moreover problem solving should not be a skill reserved for engineers and specialists, if you truly desire to harness the creativity and innovation of your employees then it should be seen as a fundamental skill possessed by everyone! 2 Day Workshop Our 2 day workshop will provide delegates with a simple yet effective 8 step systematic tool for problem solving. They will understand how, when applied correctly, this tool can be used to improve Safety, Quality & Efficiency. They will also understand how problem solving in teams can create even greater benefits in terms of innovation and motivation Managers, Supervisors, Engineers and Specialists Learn how to Define the real problem Use and present data to clarify the point of cause of the problem Study the problem to ensure complete understanding Select countermeasures and evaluate effectiveness Monitor the results & gain greater benefits through effective yokoten

11 4S Organisation 1 Day When: Cost: 450 (+23% VAT ) per person (up to a max of 4 delegates per company). 4S is a tool that when used correctly will enable the elimination of waste that contributes to the creation of mistakes, defects and injuries in the workplace. It is much more than a tool used just to provide a clean and tidy workplace! It is a management tool, a tool that ensures safety, quality and efficiency are built in to the operation. It s a tool that generates teamwork and motivation and it s a tool to enable the rapid recognition of abnormality. For these reasons it plays a vital role in supporting the Toyota Production System (TPS). To maximize the benefits of this tool the organisational culture required to sustain it in operation is of paramount importance. If used correctly 4S can be part of the process of visual control of a well planned lean system. 1 Day Workshop Our 1 day workshop will provide delegates with a practical understanding of 4S and how it can be sustained in the organisation. They will through a series of exercises and shop floor study grasp the key benefits of a successful 4S program and the role it plays in a well planned lean system. The meaning and true purpose of each element. How to use the tool to engage and motivate employees Managements role in sustaining 4S How to effectively implement 4S in their own organisations. All levels up to supervisor and managers where appropriate

12 Terms & Conditions 1. Participation Fee The participation fee for this event is due upon online registration. 2. Cancellation Policy No refunds will be issued on cancellation. The fee is non-refundable however, if you are unable to participate you may nominate a substitute from your company to attend in your place. Names of substitutions should be received in writing to Richard Keegan richard.keegan@enterprise-ireland.com 3. Invoicing Policy Invoices will be issued after the event has taken place. 4. Methods of payment Payment can be made by credit card at the end of the online registration process. If you experience problems when paying on-line please contact Accounts Receivable on or Enterprise Ireland reception at and ask for Accounts Receivable. 5. Enterprise Ireland Privacy Policy Users of Enterprise Ireland's website are advised to read the following Privacy Policy, illustrating our compliance with the Data Protection Acts of 1988 and 2003 with regards to the processing of information collected on our site. This Privacy Policy contains an explanation of what happens to personal data that you choose to provide to us, or that we collect from you whilst you visit this site. We do occasionally update this Policy so please do return and review this Policy from time to time. Information we collect in running and operating this website we may collect and process certain data and information relating to you and your use of this site. This data and information is detailed below: The Enterprise Ireland site utilises web server technology which monitors and logs IP information from all visitors to the site including but not limited to traffic data, location data and other communication data. This information does not contain any personal details of users and is stored and accessed strictly for statistical purposes. Information that visitors provide to us as a result of filling in forms on our website, such as when a visitor registers and pays online for an event. Information provided to us when our visitors communicate with us electronically for any reason. The Enterprise Ireland site does not use cookies. Online Booking & E-Payments The Enterprise Ireland website facilitates online booking of its events.

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