Implementing Lean Thinking isn’t as easy as reading about it in a book. Research indicates that as much as 80% of the success of a Lean implementation relies on how the training was conducted and how management create strong processes to ensure enduring Lean success.
Potential Funding
Funding is available through Callaghan Innovation. The Better By Lean programme is run through Auckland University and qualifying companies that attend the two day course are eligible for co-funding (50% up to a maximum of $20,000 excluding GST). Further information can be found at Better By Lean.
The Lean Group is an approved provider for the Better By Lean programme.
Lean Transformation
Our Lean Transformation courses focus on creating a culture of continuous improvement at all levels of the organisation, working with senior managers and employees. Our Competitive Edge programme results in fantastic engagement and ensures strategic processes are established for key Lean processes to sustain your progress into the future.
Competitive Edge
Competitive Edge is designed as an organisational change programme that delivers the following:
- An individually designed best practice Lean programme with expert mentoring and support.
- Implementation processes that are aimed at creating internal capability and the capacity to lead and sustain change.
- Modules that deliver best practice Lean theory, process improvement, tools and work practices.
- Creation of a roadmap to ensure engagement over the long term.
How does the programme work?
The programme focuses on two levels of the business:
- Strategic Leadership Team (SLT), consisting of the CEO/GM and other senior managers and support personnel, up to 12 people.
- Productivity Improvement Team (PIT), consisting of employees and support personnel on the shop floor, up to 12 people. There is a strong focus on workplace application of PIT training.
The training programme is structured to train both the SLT and PIT in foundational lean tools. The key focus for PIT teams is how to apply the tools, and for the SLT is how to lead and manage the lean processes.
The Competitive Edge programme has a reputation for delivering significant business outcomes.
Day Courses & Workshops
Day Courses & Workshops provide an opportunity to educate your staff a few at a time in key topics. These courses are uplifting & engaging and suitable for a wide range of previous knowledge of Lean Thinking.
Introduction to Lean
The Introduction to Lean is an introduction to the basic principles of Lean Thinking, including:
- What is Lean
- 5 Principles of Lean
- 7 Forms of Waste
- 5S Workplace Management
- Value Stream Mapping
- Best Practice Implementation
- Secrets to Lean Success
Learn how you can transform your business by learning to see the process, recognising waste in existing processes, identifying and making improvements, organising the workplace – all while engaging and empowering your staff.
Who should attend?
Senior Managers, CEOs, CFOs and Business Owners who are seeking to understand Lean Thinking.
Introduction to 5S
This workshop introduces participants to 5S, one of the foundational tools of Lean. The day starts with an overview of Lean and the 7 Forms of Waste, and includes:
- What is 5S and why is it so important?
- Lean Simulation Game to help understand lean concepts
- 5S Auditing and its importance
- Challenges of implementing 5S
- Visual Communication
Where possible this workshop is hosted at a company who is already doing 5S, and includes a factory tour, Q & A session and a practise 5S Audit in a real workplace.
Who should attend?
Senior Managers, CEOs and Business Owners who are seeking to understand 5S. The workshop can also be run as a training course for your staff.
Leading Lean
Unfortunately many change initiatives fail to provide lasting change. In this course, participants will understand the principles of Lean and examine:
- Why change fails
- How to mitigate against the failures
- Leadership in a Lean context
- Understanding how people react to change
Where possible this workshop is hosted at a company who has been going on the Lean journey themselves and will include a workplace tour and an opportunity to ask questions of their leadership about the successes and challenges of implementing lean.
Who should attend?
Senior Managers, CEOs and Business Owners who are seeking to understand how Lean is implemented.
Short Courses
Our short courses are designed to either be run as stand-alone courses or in conjunction with a Lean Transformation. These courses are typically between 3 – 5 days long and often require project work to be done between the fortnightly training sessions.
Value Stream Mapping
On average, less than 10% of what we do adds value to the customer. Value Stream Mapping (VSM) is a key technique in the lean toolbox, which focuses on which steps in your process add value and which don’t. It can be applied to any process or part-process with equal success.
This short course starts with an introduction to the seven forms of waste, and enables your organisation to:
- Examine the flow of information and materials needed to produce a product or service
- Understand where the largest sources of non-value adding waste are
- Define a less wasteful future state
- Develop implementation plans to get there
An extra day can be added to set up a change management system for your organisation. The Opportunity for Improvement (OFI) system will become the key process for managing staff ideas and turning them into reality.
Course Location and Duration
This 3-4 day course is run on-site. Training is usually fortnightly sessions of 6 hours each. Project work is required between sessions.
Who should attend?
A cross-functional team with experience in the selected process, including senior managers, team leaders, trainers, support staff and operating staff.
The Competitive Edge programme has a reputation for delivering significant business outcomes. See the Case Studies page for more information.
SMED/Quick Changeover
Quick Changeover, also known as Single Minute Exchange of Dies (SMED), is a technique for reducing the downtime associated with machine set-ups and changeovers. Traditional manufacturing attempts to overcome this downtime by running large batches of product, spreading the cost of the changeover across the run to keep the unit cost in check. However, Lean teaches us that large batches result in over-production, inventory, transport and waiting wastes.
The course builds on your foundations of 5S and VSM to specifically examine changeover processes and reduce them.
Course Location and Duration
This 3-4 day course is run on-site. Training is usually fortnightly sessions of 6 hours each. Project work is required between sessions.
Who should attend?
A cross-functional team with experience in the selected changeover, including maintenance and operational managers, team leaders, maintenance and operating staff and internal support functions.