MANTEC offers a variety of LEAN courses that can help you to transform your company or operation by learning how to plan effective change processes, overcome barriers, and learn proven tips and techniques for sustaining change.
Tools for Managing Change
This two-part workshop will teach participants how to identify the stages of change, manage them successfully, and lay the foundation for an organization to accommodate and ultimately embrace change.
- Part 1: Helping Organizations Embrace Change Through Effective Communication
Good communication is critical during changes within an organization. This course helps people understand their preferred communication style, how to determine the preferred style of others, and how to effectively communicate with anyone.
- Part 2: Solving Problems/Managing Conflict/Building Better Teams
Change sometimes creates conflict. In this course, participants will learn how to effectively lead a group through team problem solving and deal with conflict that may occur. Register here.
Change Agent/Kaizen Methodology
Learn how to transform your company or operation to LEAN by stimulating action, building velocity, and sustaining momentum. You will learn how to plan effective change processes, use influence and persuasion to overcome barriers, and learn the proven tips and techniques for sustaining change. This workshop will explain what a Kaizen is, how to prepare for one, how to conduct a Kaizen, and how to measure the changes in performance. Participants will also learn how to deal with common problems during a project. Register here.
5S: Workplace Organization
This course follows the Train and Do format for a 5S project. Participants learn the 5S approach for workplace organization: Sort, Set in Order, Shine, Standardize, and Sustain. Immediately after the theory is presented, participants apply the 5S concepts in a real-life situation. Results of this 3-day project are always impressive and much better than most people expect. Register here.
Quick Changeover/Setup Reduction
This course teaches the fundamental principles of set-up reduction and reducing waste. It is based on the works of Dr. Shigeo Shingo and his Single Minute Exchange of Die System of Setup Reduction. The results of applying these principles and testing the new process typically result in AT LEAST as 25% reduction in Changeover time in 3 days. Like the other Train and Do projects, this is not just theory. Under the guidance of an expert, the theory is applied to a real-life situation. Register here.
Learn how linking and balancing process steps can reduce process lead times by as much as 95%, work-in-process by 90%, and floor space by 50-75% while increasing productivity by 40% or more. This hands-on course teaches how to create a continuous flow process through 5-steps for designing and implementing work cells. Register here.
Value Stream Mapping
This course teaches the principles of Value Stream Mapping. Participants immediately apply this information in a real manufacturing company. The value stream maps will include both product flow and information flow. The first step is to document the Current State. Upon completion of the Current State Value Stream Map, participants will be ready to analyze the process for waste and create an improved Future State Value Stream Map by working through a structured series of questions. The result will be to identify mini-projects or kaizens that, when completed, will improve the entire Value Stream. Through this Train and Do approach, participants will not only know the theory, but will be able to do a Value Stream Map themselves in a real-life situation. Register here.
LEAN Manufacturing has been touted as one of the best competitive tools available in business today. It delivers dramatic savings in productivity, cycle time, and work-in-process inventories. In this one-day workshop, you become a shop floor employee building simple products. You will learn by hands-on activities that reinforce the LEAN Manufacturing Principles. You will move from the presentation format to the shop floor three times during this workshop to apply the concepts that you learn. Everyone will learn to see the waste in a process and how to eliminate the waste using the Lean tools. Register here.
LEAN for Business Processes
LEAN for Business Processes helps companies with any type of administrative function to streamline information flow – the gathering, improving, movement. and storage of information. Just like LEAN for the factory floor, LEAN for Business Processes focuses on reducing total cycle time – in this case, the time between orders being placed and when payments are received. Basic process mapping techniques will also be taught and immediately applied to a simulated office process to identify waste and develop improvement plans. Emphasis will be placed on cross-functional process mapping. This full-day workshop combines classroom instruction with interactive live simulation where class participants take on the roles of managers and workers within an office. Register here.
Daily Performance Management/A3
What you measure is what your employees will focus on. Most customers primarily measure their suppliers based on Quality, Delivery, and Cost. Those same measurements on the shop floor are vital to continuously improving most company operations. Capturing the right measurements and having a process to review and improve them is of vital importance to the success of your LEAN transformation. With the right measurements in place, you can build and sustain momentum and win the support you need. With the wrong measurements in place, you are falling on your sword and not leveraging the efforts of your teams to successfully focus on critical bottom line issues. In this course, you will learn how world-class companies attain 100% employee involvement, how to improve the culture of your organization, and how to link company strategies to plant-floor visual measures through SQDC boards (Safety, Quality, Delivery, and Cost). The 2-day course will also include how to use the A3 problem solving process for team-based problem solving and training via simulation on basic root cause problem solving tools (5 why’s, fishbone analysis, pareto charts). Attendees will be able to take back to their work environment the tools to drive effective and continuous improvement. Register here.
Total Productive Maintenance (TPM)
This 3-day workshop is a production-driven improvement methodology that is designed to optimize equipment reliability while improving safety, and ensuring efficient management of plant assets through the use of employee involvement and engineering. TPM allows you to tap into the “hidden capacity” of unreliable and ineffective equipment. Learn how manufacturers have improved productivity, quality, customer service, and safety levels by reducing unplanned downtime as much as 40-60% through this operator-based maintenance program. During this course, major topics will include learning and applying the Overall Equipment Effectiveness (OEE) measure, a hands-on introduction to Predictive Maintenance techniques (such as thermography, vibration analysis, and ultrasonics), and assistance identifying and correcting safety and ergonomic problems. Register here.
Learn how Pull sSystems work, the benefits versus production based on forecasts, and if Pull Systems are right for your business. This workshop allows participants to explore the process of designing and implementing Pull Systems/Kanban through classroom instruction and hands-on production simulations. Pull Systems control the flow of resources in a production process by replacing only what has been consumed. It employs customer order-driven production schedules based on actual demand and consumption rather than forecasting. The 2-day course will start with understanding how to implement a Pull System with customer orders, run an entire company based on Pull Systems, and interact with suppliers with Pull Systems. You finish by designing a Pull System for a work cell. Register here.
Effective Team Leadership
Organizations know they need the power of teams to achieve their best results. Effective facilitation is what transforms an average team into a high-performing, highly successful team. This can create a special challenge for anyone leading teams or meetings. This workshop will enable participants to experience the roles and techniques of facilitation as they are learned. Participants will facilitate small group activities and will receive feedback and coaching after each performance. In this three-day workshop you will gain an understanding of the facilitator role and the importance of managing meetings; steer teams through a variety of decision-making processes; spark creativity and innovative ideas from all; assess a team’s needs; deal with challenging team behaviors; and, design effective team processes. Register here.
Front Line Leadership
Front Line Leadership is designed to help first-line supervisors and managers understand the keys to success in the LEAN enterprise environment. In these five half-day sessions you will learn the tools and techniques to enhance your ability to build an empowered workforce while immediately applying what you learn. The purpose of this training is to understand and address certain cultural changes required to ensure a successful transformation to a LEAN environment. This program is schedule on request. Register here.
Light LEAN Principles
This is the first step to understanding LEAN Manufacturing from an overview standpoint. This 4-hour course combines classroom work and live simulation where participants manufacture Lego airplanes simulating manufacturing principles. There is open discussion, simulation, and identification of the eight wastes that an organization must reduce to be competitive in today’s marketplace. This course is scheduled upon request. Register here.
LEAN Manufacturing for Food Processors
This highly interactive one-day course provides an overview of the principles of LEAN manufacturing. Participants learn how LEAN manufacturing tools and programs apply in today’s food processing environment. The course combines lecture and live simulation that gives participants and immediate opportunity to apply the principles learned in the class. Four rounds of a food processing factory simulation provide the setting for applying the continuous improvement techniques and tools of LEAN. LEAN principles incorporated over the course of the simulation allow participants to transform a chaotic, inefficient process to a highly productive and efficient production process, where waste has been systematically eliminated. This course is scheduled upon request. Register here.
LEAN Working Group
LEAN Working Group is held every other month. The mission of the LEAN working groups is to assist each other in using LEAN principles and techniques to continuously improve company profitability and competitiveness by providing a forum to:
- Discuss common or unique LEAN application experiences.
- Develop new business alliances.
- Share resources that have proven useful.
- Participate in LEAN Kaizen (training) events.
The Agenda includes:
- Plant Tour by the host company.
- Discussion about training needs of the group and upcoming courses being offered by MANTEC.
- A topic every other month with a case studies and discussion led by MANTEC.
Are you searching for the answer to, “How can our continuous improvement process survive and thrive”? Toyota Kata addresses this challenge providing the framework for a sustainable problem-solving culture incorporating targeted experimentation and personal learning. In this workshop, you will learn about two specific behavior routines, or kata. First, Improvement Kata is a repeating routine of establishing challenging target conditions, working step-by-step through obstacles and learning from problems encountered along the way. Second, Coaching Kata is a pattern of teaching improvement kata to employees at every level, ensuring that it permeates their thinking and actions. Participation in the Improvement Kata simulation makes it easy to understand how the Toyota Kata trajectory components come together. The interactive simulation brings Kata “to life” as team members PDCA their way through the Kata process toward a challenge and target conditions. Register here.
LEAN for Executives
Implementing LEAN Manufacturing is an important decision that can lead to significant Return on Investment. This workshop will explain what LEAN manufacturing is and what it can do for your business, typical challenges on the journey, and the executives’ roles. The interactive program includes two simulations: one to understand the cash flow and financial statement implications; and, one to experience LEAN by identifying waste, implementing various LEAN tools, and eliminating the waste. Register here.