ACADEMY ACADEMY. Leanop 2010 all rights reserved Leanop 2010 todos os direitos reservados

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1 ACADEMY ACADEMY

2 Table of contents What we do Academy Alignment Flow TQM TPM Management of Routine Lean Office Certification of competencies

3 What we do Accelerating learning by doing. Going outside of day-to-day business in order to improve it. Training available at customer site or in our training site. 3

4 Trainings Alignment Flow TQM Coaching and Leadership Operational Management Systems Change Management Policy Deployment / Hoshin Kanri Balance Scorecard Leadership Profile Performance Appraisal Lean Awareness JIT - Creating Flow JIT - Creating Flow for Process Industry SMED- Single Minute Exchange Die JIT - External Logistics Lean Planning Extended Enterprise Lean Design Autoquality Managing Quality in the Extended Enterprise Problem Solving TPM TPM Awareness TPM Production System AM Autonomous Maintenance PM Planned Maintenance FI Focus Improvement EM Early Management ET Education and Training Management of Routine Lean Facilitator Leadership for Team Leaders Measures and Reviews 5S and Visual Management Management of Improvement Project Management TWI Training Within Industries Lean office Lean Office Awareness Flow Office Office 5S 4

5 Alignment From: A loss of potential in the organization, even thought there s a huge amount of energy spent by individuals. Non coordinated initiative Tasks and objectives not well defined. To: An organization that takes the most of everyone in the organization. Focusing creativity and initiative. Methodologies 5

6 Coaching and Leadership Motivation Understand how to drive an organization towards excellence. Going from Managing to Leading. Create a good work environment Handle conflicts Give feedback Develop people Manage Creativity How to Walk the Talk Lead work sessions Delegation Escalation Top Management, Middle Management 16 Hours Training - Alignment 6

7 Operational Management System Motivation Defects Availability Productivity Cost Service Level Understand how to create and improve an Operations Management System. Understand how to align the organization. Training - Alignment 7 What is a management system Impact of a management system in the day-to-day Roles and responsibilities How to align targets Understand how to link behaviors and performance Business Needs Mission, Vision, Objective and Strategy Top and Middle Management 16 Hours

8 Change Management Motivation Learn how to change mindsets. Learn how to proactively reduce resistance. Learn how to deal with resistance. Top and Middle Management 16 Hours Leading Change Steps of Change Paradigms Sponsoring an initiative Insuring mindset change Change agent Learning organization How to create the energy for the change Training - Alignment 8

9 Policy Deployment / Hoshin Kanri Motivation Understand how to create an integrated system with objectives for all departments and management units. Understand how to define initiatives according to the company s strategy. Training - Alignment 9 Masterplan Reviews Roles and responsibilities KPI s 8 Hours Goals Cascading Project management Top and Middle Management and Support Departments

10 Balance Scorecard Motivation Defects Availability Productivity Cost Service Level Understanding how to align measures with business needs. Understanding how to set targets. Balance Measures Setting targets Cascading KPI s Translating business needs Measuring results and practices Frequency of measures Reviewing of measures Top and Middle Management 16 Hours Training - Alignment 10

11 Leadership Profile Motivation Understand the concept of company s culture. Understand how to apply a system of good practices for leaders. Training - Alignment 11 8 Hours Mission, Vision and Values Leadership and behavior Soft skills and accountability Stakeholder management Team management Top and Middle Management and Support Departments

12 Performance Appraisal Motivation Defects Availability Productivity Cost Service Level Understanding how to align measures with business needs. Understand how to define goals. Job description Evaluation system Feedback Active listening SMART goals Project management Managers and Human Resources 8 Hours Training - Alignment 12

13 Flow Improving the overall performance of the company by creating flow, leading to substantial reductions of lead time, improving flexibility and service level. Methodologies 13

14 Lean Awareness Motivation Productivity Defects Cost Understand the basic concepts of Lean. Understand the Lean journey. Engagement of everyone. Paradigms Autoquality Muda,Mura,Muri 7 Muda Muda Tour 5S TWI Poka-Yoke Visual Management All employees 4 Hours Training - Flow 14

15 Training - Flow 15 JIT Creating Flow Motivation Defects Service Level Lead Time Cost Working Capital Understand the concept of flow and JIT and be able to apply. Understand the relation between quality and flow. Takt time VSM/VSD Top and Middle Management, Team Leaders, Logistic Operators and Leading Operators 16 Hour Yamazumi Line balancing Kanban Supermarket Mizusumashi Logistic train Heijunka Line leveling Standardized work Border of the line Pull System Demand amplification effect

16 JIT - Creating Flow for Process Industries Motivation Defects Service Level Lead Time Cost Working Capital Understand the impact of local optimization in all the supply chain. Understand the relationship between quality and flow. Conteúdos Kanban Supermarket Heijunka Line leveling Yamazumi Line balancing Takt Time Standardized work Border of the line Poka-Yoke Pull System VSM/VSD Demand amplification effect Top and Middle Management, Team Leaders, Logistic Operators and Leading Operators 16 Hours Training - Flow 16

17 SMED Single Minute Exchange Die Motivation Lead Time Cost Working Capital Understanding how to reduce set-up time. Training - Flow 17 Maintenance, Production, Engineering 8 Hours SMED steps Creating a standard method Internal & external activities Converting internal to external activities Techniques to decrease internal and external activities

18 JIT External Logistics Motivation Defects Service Level Lead Time Cost Working Capital Understanding how to create flow with suppliers and customers. Reduction of variability (Mura) in all the supply chain. Creating an extended Lean Enterprise. Milk-Run Kanban Supply Chain, Logistics and Production 16 Hours Heijunka- Line leveling Supermarket Load optimization Global optimization vs. point optimization Packaging Value Stream Design Amplification effect beer game Global cost Training - Flow 18

19 Lean Planning Motivation Defects Service Level Lead Time Cost Working Capital Understand how to plan in a Lean environment. Understand the role of planning in a Lean environment. Training - Flow 19 Managers and Planning 8 Hours Capacity planning Kanban system Heijunka Lead time Total cost analysis Supply chain planning Supermarkets

20 Extended Enterprise Motivation Defects Service Level Lead Time Cost Working Capital How to drive improvement in the extended enterprise. Understanding how to link all the value chain. Top and Middle Management, Purchasing and Sales 8 Hours Workshops in suppliers Workshops with customers Complexity studies Total cost studies Value Stream Manager Defining value for the customer Understanding how to reduce variability (Mura) Training - Flow 20

21 Lean Design Motivation Defects Service Level Lead Time Cost Working Capital Understand how to create new lines. Understand how to launch new products. Training - Flow 21 Product development, Engineering 16 Hours Building in existing products Line simulation Assembly simulation Product and Process Matrix Risk Analysis Complexity studies Creating robust products How to involve the organization

22 Methodologies TQM Achieving sustainable improvements in quality by engaging everyone in the organization. Prioritizing problems, creating immediate countermeasures, solving the root cause and creating poka-yoke systems. 22

23 Autoquality Motivation Lead Time Defects Cost Understand how to manage quality in day-to-day business. Understand how to drive quality improvement. Training - TQM 23 Middle Management, Team Leaders, Quality Operators and Leading Operators 8 Hours Autoquality Matrix Day-to-day problem solving Root Cause Analysis Pareto Poka-Yoke Visual Management Standard Standard Work SDCA/PDCA

24 Managing Quality in the Extended Enterprise Motivation Lead Time Defects Cost Drive significant improvement in quality by involving all the extended enterprise. Creating a quality system that gives quick feedback. After sales, Sales, Quality Engineer,Purchasing, Product Development 16 Hours Developing a robust quality system Defining the CTQ (Critical to Quality) VOC Voice of the customer VOP Voice of the process Involving all the value chain in quality (customers and suppliers) Training - TQM 24

25 Training - TQM 25 Problem Solving Motivation Defects Availability Productivity Cost Service Level 8 Hours Be able to pick which level of problem solving to apply. Understand how to apply formal problem solving. Transforming problems into opportunities. Differential thinking Root Cause Analysis Day-to-day problem solving Ishikawa Poka-Yoke Visual Management Standard SDCA/PDCA DMAIC Top Management, Midle Management, Team Leaders, Logistic Operators and Leading Operators

26 AM PM FI ET SHE Office EM Methodologies TPM Improving equipment efficiency, and reducing maintenance cost by engaging everyone in the organization: 1. Eliminate forced deterioration 2. Eliminate Design Weaknesses 3. Time Base Maintenance 4. Condition Base Maintenance TPM 5S 26

27 TPM Awareness Motivation Availability Defects Cost Understand TPM as a management system. Understand the benefits of TPM. Training - TPM 27 All employees 4 Hours Maturity phases Implementation Steps TPM organization Steering Committee Local Committee Pillars Autonomous groups Links between pillars Roles and responsibilities Mission of each pillar

28 TPM Production System Motivation Availability Defects Cost Learn how to reduce losses through implementation of TPM. Top and Middle Management, Team Leaders 8 Hours The maturity phases for the Implementation of TPM Implementation strategy TPM pillars Links between pillars Steering committee Local committees Roles and Responsibilities Skills to be develop Communication Platform Training - TPM 28

29 AM Autonomous Maintenance Motivation Availability Defects Cost Understand the role of Production in a TPM environment. Understand how to improve equipment availability. Training - TPM 29 AM Steps Maintenance and Production 16 Hours Pillar roles and responsibilities Links with other pillars Pillar roll-out Initial Cleaning OEE Types of stoppages Competences to be develop in operators

30 PM Planned Maintenance Motivation Availability Defects Cost Understand the role of Maintenance in a TPM environment. Understand how to improve equipment availability. PM steps Maintenance and Production 16 Hours Pillar role and responsibility Links with other pillars Pillar roll-out Types of Maintenance Run to fail Time based Maintenance Conditional based maintenance Maintenance Cost Training - TPM 30

31 FI Focus Improvement Motivation Defects Service Level Availability Cost Understand the different ways to solve focuses problems. Understand the role of the FI pillar. Training - TPM 31 Support function, pillar leader and member 8 Hours Roles and responsibilities of the pillar Links with other pillars Pillar structure Pillar roll out FI tools Losses Three Problem Solving stories Competences and Skills needed

32 EM Early Management Motivation Defects Service Level Availability Cost Understand how to introduce new equipments in order to reduce ramp-up. Engineering, Product development 8 Hours Pillar role and responsibilities Pillar structure Links with other pillars Learning with current equipment How to involve suppliers Involving operators Case studies Pillar steps Risk Management Capacity Calculation Training - TPM 32

33 ET Educação and Training Motivation Defects Service Level Availability Cost Understand how to create competences in all the organization in order to drive improvement. Training - TPM 33 Human Resources, Maintenance and Production 16 Hours Pillar role and responsibilities Pillar steps Managing versatility Training center Cost, benefit of training Job descriptions Training techniques Self development tools

34 Metodologia Management of Routine How to deliver sustainable results and to drive improvement every day. Balance Score Card Reviews Problem Solving 5S and Visual Management Leadership and Coaching TWI Team Work 34

35 Lean Facilitator Motivation s Learn how to facilitate group work. Be able to train. Training Management of Routine 35 Support functions, Methodology leaders, Office Leaders and trainers 8 Hours Leading meetings Leading work sessions How to manage creativity Giving training Group dynamics Training methodologies Facilitating exercises

36 Leadership for Team Leaders Motivation 8 Hours Understand how to lead a team taking the best out of every member. Understand how to coach. Understand how to inspire people. Day-to-Day Coaching Handle conflicts Delegation Escalation How to create a positive work environment Management Vs. Leadership Giving Feedback Leading meetings and workshops Team leaders Training Management of Routine 36

37 Measures and Reviews Motivation Productivity Defects Cost Training Management of Routine 37 8 Hours Understand how to lead a meeting. Understand when to escalate, when to delegate and when to create a problem solving group. Review days performance Different level of reviews Leading meetings Taking actions Setting up Team Boards Roles and responsibilities Improving participation in meetings Management and Team Leaders

38 5S and Visual Management Motivation Productivity Defects Cost 8 Hours Understand how to optimize workstations. Understand how to improve housekeeping and productivity at the same time. Visual Management Standard SDCA/PDCA 5S Muda 5S Audit Top Management, Midle Management, Team Leaders, Logistic Operators and Leading Operators Training Management of Routine 38

39 Management of Improvement Motivation Defects Availability Productivity Cost Service Level Training Management of Routine 39 Managers 8 Hours Understand how to drive improvement in an organization. Understand which methodologies to apply in each case. Transforming the company DNA. Support structure Roles and responsibilities Communication platform Best practices Conducting interviews Audit system Gemba walks Review system Improvement office Value Stream Manager

40 Project Management Motivation Defects Availability Productivity Cost Service Level Learn how to manage a project from concept to implementation. Support Engineers, Support functions 16 Hours Return on Investment Risk Analysis Stakeholder Management Data Analysis A3 reporting Planning Reviewing Presenting to different levels of the organization Running crisis Training Management of Routine 40

41 TWI Training Within Industries Motivation Defects Availability Productivity Cost Service Level Understand how to train people in a fast and effective way. Understand how to run versatility. Training Management of Routine 41 Team Leaders, Leading Operators, Maintenance, Engineering and Office Leaders 8 Hours Job Instruction Training (JI) On the job training Learning Process Roles and responsibilities in training How to Improve job methods Documentation needed for training How to manage skills and versatility

42 Methodologies Lean Office Learn how to create flow in an office environment leading to substantial improvements in service levels and balance between processes. 42

43 Lean Office Awareness Motivation Understand the basic concepts of Lean Office. Understand the difference between value added and non value added activities. Training - Lean Office 43 All office employees 8 Hours Waste (Muda) Sources of variability (Mura) Relation between motivation and performance Paradigm

44 Flow Office Motivation Defects Lead time Productivity Cost Understand how to improve flow in an office environment, leading to reductions of lead time and quality improvements. Managing and decreasing Variability Office Kanban Supermarket Heijunka Leveling Yamazumi Balancing Takt Time Standardize work Pull System VSM/VSD 16 Hours Amplification effect Top and Middle Management and Office Leaders Training - Lean Office 44

45 Office 5S Motivation Productivity Defects Cost Improving the office work environment. Improvement office productivity and workers satisfaction. Improving Housekeeping. Training - Lean Office 45 5S All office employees 8 Hours 5S in an IT enviroment Standard PDCA/SDCA Waste (Muda) Visual Management Office 5S audits

46 Train the trainer Accelerating the knowledge of the leaders Transferring knowledge to create the autonomy within the organization. Certifying competences. Trainees will perform projects and only after successful application they will get the certification. 46

47 Certification of Competencies Lean Manager Training + Implementation Lean Coach Knowledge and competencies to lead a Lean initiative, manage change and align stakeholders. Knowledge and competencies to lead teams of global improvements in all the Lean methodologies. Lean Facilitator Team Leader Knowledge and competencies to lead improvement teams focused in one of the methodologies (Flow, TPM, TQM or Lean Office). Knowledge to daily lead and motivate teams focused in continuous improvement of the QCDM goals. 47

48 Certifications Capitão Team Leader Equipa Conhecimento Knowledge improve para liderar daily performance e motivar by equipas leading no and diaa-dia, motivate focando-se teams in continuous na melhoria improvement diário dos to achieve objectivos QCDM. objectives. Training Curso + + Implementação Implementation Lean Awareness Measures and Reviews, Management of Improvement TWI Leadership for Team Leaders 48

49 Certifications Lean Facilitator Knowledge Conhecimento and e competencies competências to para lead liderar improvement teams melhorias focused em equipas in one of focadas the methodologies numa das (Flow, TPM, metodologias TQM, Problem (Fluxo, Solving TPM, TQM or Lean ou Lean Office). Office). Training Curso + + Implementação Implementation Lean Awareness JIT Creating Flow Autoquality 1. TPM Awareness 2. Autonomous Maintenance 3. Planned Maintenance 4. Focus Improvement OR 1. SMED 2. JIT External Logistics 3. Lean Planning OR 1. Problem Solving 49

50 Lean Coach Certifications Conhecimento Knowledge and e competencies competências to para lead liderar teams equipas of de global melhoria improvements global em in todas all the as LeanOp metodologias LeanOp. methodologies. Training Curso + + Implementação Implementation Lean Facilitator 1. SMED 2. JIT External Logistics 3. Lean Planning 1. Problem Solving 1. TPM Awareness 2. Autonomous Maintenance 3. Planned Maintenance 4. Focus Improvement 1. Lean Office Awareness 2. Office Flow Leanop todos Office os direitos 5S reservados 50

51 Certifications Lean Manager Conhecimento Knowledge and e competencies competências to em lead liderar a Lean uma iniciativa initiative, Lean, manage gerir change a mudança and align e alinhar stakeholders. os stakeholders Training Curso + + Implementação Implementation Lean Coach 1. Lean Facilitator 2. 5S & Visual Management 3. Management of Improvement 1. Coaching and Leadership 2. Policy deployment/hoshin Kanri 3. Balance Scorecard 4. Leadership Profile 51

52 Recommended books William C. Byham, 1998 Ballantive Books ISBN: John Kotter & Holger Rathgeber, 2006, Pan Macmillan ISBN: Taiichi Ohno, 1988, Productivity Press ISBN: Kyoshi Suzaki, 1993, The Free Press ISBN: Kyoshi Suzaki, 1987, The Free Press ISBN: Tokutaro Suzuki, Productivity Press; 1 edition (1 May 1994) ISBN: Shrinivas Gondhalekar & Payal Sheth, 2005, Indus ISBN: Jeffrey Liker, 2004 McGraw- Hill ISBN: Jeffrey Liker, 2004 McGraw- Hill ISBN:

53 Founder of leanop Nuno has been working in very diverse manufacturing sectors (plastic injection, automotive, cranes, precision machinery, agricultural equipment and food manufacturing) for several years and applying Lean methodologies in the last 6 years. He started applying Lean as a production supervisor in Faurecia, he lead a multisite European Lean initiative at CNH, Case New Holland (Fiat group), then he moved to the Nestlé headquarters where he participated in the design of a worldwide Lean initiative. Nuno earned a Masters in Mechanical Engineering from Universidade de Aveiro having passed one year at KTH in Stockholm. He holds a 6sigma green belt. He is fluent in Portuguese, English, French and Italian. 53

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