Lean Expert and Trainer Development

Transcription

1 PROGRAMME 2015 Lean Expert and Trainer Development Seeing. We open factory gates for you. Learning. Acting. Living. Lean know-how for the development of your employees. Lean do-how for the development of your company. Securing performance and progress through daily leadership and coaching. The know-how and actions of your improvement experts are the levers for your competitive leadership. Your multipliers will delight you and provide lasting effects. Martin Haas, CEO, Staufen AG Academic partner: Experience Lean Excellence on-site with our BestPractice Partners:

2 . 2 INTRODUCING THE STAUFEN ACADEMY Welcome On behalf of all partners and participants, you are cordially invited to the Staufen Academy. Our main focus is on qualification and benchmarking. Companies are left behind when they fail to develop and improve continuously. Qualified in-house experts are the prerequisite for exploiting your improvement potentials, and at the same time represent a competitive factor that should not be underestimated. Top performance is the goal, Lean Transformation is the way. As an international advisor on Lean Management, we develop companies and their staff from turnaround through to excellence through active exchange. 13 offices in 9 countries projects in 25 countries and 14 languages Martin Haas Wilhelm Goschy Dr. Jens Zimmermann Executive Board, Staufen AG APPROVED AND RECOMMENDED For more than 15 years we successfully train improvement experts. In 2010 the Institute for Production Management, Technology and Machine Tools (PTW) of Darmstadt Technical University certified our programme. After the successful completion of levels I and II you will be awarded the Lean Expert Certificate and after the successful completion of levels I, II and III you will be awarded the Lean Trainer Certificate. IN-HOUSE TRAININGS We design tailor-made in-house trainings, based on your needs and requirements, to be carried out in practical fashion on-site in your company. We do this by actively involving your employees and working on your specific problems, issues and processes. A wide range of Lean topics of your choice is presented at /en/academy INTERNATIONAL PARTNERS Our offices in China, Brazil, Italy, Poland, Hungary, Czech Republik, Slovakia and Switzerland also provide Lean Management trainings together with our BestPractice partners in the local language:

3 . 3 Content and structure of the certified training programme Lean Expert LEVEL 1 LEVEL 2 LEVEL 3 Lean Development Training Basic Training communication skills and lean know-how Lean Manufacturing Training Lean Assembly / for high volume production with short takt times Lean Assembly / + + for low volume production with long takt times Lean Administration Training Lean Purchasing Training Advanced Training social, leadership and teaching skills Lean Logistics Training Lean Trainer LEVEL I LEVEL II LEVEL III Mediation of lean principles; improvement of moderation / presentation skills: future lean experts are familiarised with the basics of lean management and lean processes, and improve their presentation and moderating skills. Area-specific further development of specialist and methodological expertise regarding lean management: future lean experts choose the specialist workshop that is relevant to them, and thereby further develop lean methods and tools. Increasing presentation and organisational competence: the future lean trainers improve their organisational and presentation skills. At the foreground is the acquisition of the ability to teach others to understand topics, in particular in the area of lean processes. All modules can be combined in any constellation and may be booked separately. In that respect please note that the training programmes are built on each other in terms of content. This is why adherence to the sequence is recommended. Select the specialist training depending on the trainer s area of focus. ADDITIONAL OPTION We would like to assist you in every phase of the lean transformation of your business by actively involving your employees and working on your specific problems, issues and processes. If you would like us to train a larger group, all training modules are also feasible in-house (for further page 13).

4 . 4 LEVEL 1 Basic Training Enhance your communication skills and lean know-how Future improvement experts in all areas of all industries Future lean experts and lean trainers are mainly responsible for supporting and backing up the lean transformation and enhancing the continuous improvement process (CIP). They also have to be able to efficiently manage teams. Therefore, know-how and ability in terms of dealing with conflicts, demotivation and other difficulties in the change process is required. On the one hand, our trainers provide fundamental knowledge of lean management, value adding, organising waste-minimized processes and CIP. On the other hand, you will learn about problem solving methods as well as the necessary soft skills such as moderation and presentation techniques, to be successful in your daily working environment. > Successful communication and process improvement organisation: communication basis / teaching skills / spheres of activity of the CIP office / social processes and working in teams / CIP workshops and tasks, skills, responsibilities of the trainer > Fundamentals of teaching and lean management principles: basic training lean production / communicative competence / giving and accepting feedback / practising presenting: creating and making a presentation > Lean management, presentation, analysis and problem solving: further developing a basic understanding in lean production / presentation aids / giving and accepting feedback / practising presenting / overview of problem-solving and analysis tools > Project work and personal measures plan: project planning tool: 12-week projects / exercises for project planning and, where applicable, presentation / personal measures plan You get to know the necessary tools and methods to moderate the continuous improvement process. In this respect particular attention is paid within the meaning of the CIP concept to successfully working in teams and dealing with conflicts. You learn how to efficiently manage teams. Dealing with different views, de-motivation among the involved parties and countering difficulties in the change process. Get in contact with trainers from other companies, exchange experiences and widen your network including subsequent ideas and exchange of concepts. 4 days EUR

5 . 5 LEVEL 2 Lean Development Practical and professional skills for lean development experts Innovation and product development are skills which increasingly determine a company s economic success. Only those who succeed in meeting and exceeding customer requirements in the form of lead times, budgeting and qualitative results will secure long-term competitive advantages. Simultaneously, huge potentials for effectiveness and efficiency improvements are concealed within the development divisions, due to a lacking awareness of waste. Lean Development shows that the application of Lean criteria (zero defects, flow, rhythm and pull) can also give rise to a significant improvement of project targets, such as project turnaround times and development budgets. > Principles of Lean Development: lean history and the basics of a lean company / simulation and areas for action regarding lean development > Methodological competence process : product creation process of front loading projects: avoid disturbances early / transparent control via innovation and development road maps > Methodological competence project roles : organisational structure in a lean development / duties, authorities, responsibilities of those involved in the development / management skills project management / genba management: project visualisation, normal communication, project prioritisation > Methodological competence project management (planning change projects / securing the sustainability of Lean development): critical chain project management: reducing through-put times, adhering to deadlines / introduction of a lean development system / change management: analysis planning and change process introduction / audit and continuous improvement > Methodological competence product design > Leadership competence communication / conflict management : communication and conflict management in the development environment Future improvement experts, managers and employees in the areas of research, development, design or other related areas You will learn the key tools for analysing and optimising your organisation in the workplace, on the process level and divisional level. We provide you with suggestions about implementing indicators and improving your business processes.

6 . 6 LEVEL 2 Lean Assembly for high volume production and short takt time Practical and professional skills for lean assembly experts Future improvement experts, managers and employees in the areas of assembly, planning or other related areas Are you aware of the problematic nature of excessive lead times, lacking flow principles in the assembly cells, material buffers between the work stations, large batches and non-sequenced work processes? This workshop will help you break free from conventional approaches and optimise your assembly processes with lasting effect. You will get to know the principles of low-waste and flexible assembly processes. In cooperation with SEW-EURODRIVE, we offer an innovative event concept. Through learning by doing you will organise excellent assembly processes. The inspection of plants completes this workshop. See how successful plants organise their assembly processes, and profitably implement at your own company what you have learned. > Basics of lean management and value stream design: introduction to SEW value creation system / practice simulation: sequence 1 workshop production / theory and practical implementation of value stream analysis > Just-in-time (JIT) and zero defects: zero defects culture: defect identification, rectification, avoidance / flow: reduction of lead time by chaining / planning of a perfect value stream and road map for action / layout planning for the 2nd sequence of the simulation and reconstruction of the simulation factory > Task analysis, line balancing, rhythm: theory and implementation activity analysis / simulation sequence 2: flow production including time recording / rhythm: line balancing, breathing system / stacking diagram, degree of value creation, potential assessment > Pull, layout planning and design, Cardboard Engineering part 1: Pull: pull principle, Kanban, provision of materials / layout design / cardboard engineering simulation as a cardboard model > Cardboard Engineering part 2: visualisation, line balancing diagram, two-handed analysis / detailing cardboard model, simulation of optimised processes, results projection You will learn to identify potentials and increase them in a structured process. Illustrating what has been learned on the SEW shop floor will exert a positive influence on the application at your own company. Benefit from the exchange of ideas with experienced practitioners and broaden your network to your advantage. EXPERIENCE LEAN EXCELLENCE ON-SITE AT:

7 . 7 LEVEL 2 Lean Assembly for low volume production and long takt time Practical and professional skills for lean assembly experts You are challenged with bringing bulky products to the assembly in flow? Your small series assembly, with a high degree of customer specific characteristics makes the logistics difficult? In this workshop, you will learn how large work contents can be takted and how through the use of a model mix, variations in work contents can be compensated. You will see how through a just-in-sequence material provision in pre-assembly and customer specific components directly to the line, large amounts of waste can be reduced. Future improvement experts, managers and employees in the areas of research, development, design or other related areas > One-piece-flow (OPF) and standard work: One-piece-flow as the ideal in lean production / practical exercise: recognition of waste / standard work in theory and simulation > Customer takt and cycle time: balancing cycle times through customer takt orientation / practical exercise: activity analysis in the assembly process / line balancing and model mix / practical exercise: design of a model mix assembly line / modularisation to balance of the final assembly > Assembly design: eight design principles of an assembly station within a flow process / practical exercise: layout planning for a final assembly and a pre-assembly station > Logistics connection and Cardboard Engineering: material flow control according to the Pull principle with internal and external material flows / practical exercise: planning the just-in-sequence connexion between a pre-assembly station and the main assembly line / Cardboard Engineering to simulate the pre-assembly process > Visualisation and deviation management: implementation of visualisation in the cardboard model / practical exercise: contributions from other company functions needed to optimise the flow You will get the theoretical basis for the features of lean production. You identify waste in real processes with a detailed analysis and learn to develop a flow line to BestPractice. Learn how the provision of materials from logistics can be made in takt. EXPERIENCE LEAN EXCELLENCE ON-SITE AT:

8 . 8 LEVEL 2 Lean Manufacturing Practical and professional skills for lean production experts Future improvement experts, managers and employees in the areas of production, planning or other related areas Are you aware of the problems resulting from excessive set-up times, excessive stocks, unscheduled machine downtimes and quality fluctuations? Confine them to the past! We offer you a complete intensive workshop aimed at solving or avoiding these problems. It will help you to break free from conventional approaches and optimise your production processes sustainably. You will get to know the principles of Lean and stable production processes and their effect on your daily work. In cooperation with SEW-EURODRIVE, the BestPractice plant where the workshop takes place, we offer you an innovative event concept. Through learning by doing you will create excellent production processes initially at our premises and subsequently at yours. > Basics of lean management and value stream design: presentation and introduction / theory and practical implementation of value stream analysis / principles of lean manufacturing > Just-in-time (JIT) and one-piece-flow: from workshop production to one-piece-flow: sequence production in Chaku-Chaku cells / one-piece flow in mechanical processing on a practical example / value stream design and layout planning learning by doing > Disturbance free and poor in waste, TPM, pull: learn and practice TPM / Muda check and TPM audit live in the factory / provision of resources: how to create lean support processes in production / pull: pull principle, Kanban, round traffic, container management > Technological optimisation: set-up time reduction theory and practice workshop / set-up procedure 1, 2 and 3 on site analysis and evaluation / project example: 12-week project > Improving management in the example of WIEPRO-Consulting (consultancy within SEW): theory and practice workshop / project example in machining You will learn to recognise and leverage improvement potential through a structured process. The real examples on the shop floor will help you to find ways to apply the theory learned to your own company. Benefit from the exchange of ideas with experienced practitioners and broaden your professional network. EXPERIENCE LEAN EXCELLENCE ON-SITE AT:

9 . 9 LEVEL 2 Lean Logistics Practical and professional skills for lean logistics experts You know the problems of high inventory, missing parts and supplier returns? The approach of separation of value creation and logistics, drastically changed the classic material industry. The successful application of lean methods in logistics supports the production at the location required, through BestPoint delivery within the system. Create an optimal production logistics, through the application of high frequency takted deliveries, through the introduction of a tugger train. Design the planning and control processes with continuous pull principle from customer order, through the production to delivery. > Basics of Lean Logistics: material flow control and planning, pull principle, Kanban, JIS, JIT > Internal logistics: in-house milkrun, supply methods > External logistics: external milkrun, distribution logistics > Planning and control: order processing, levelling and smoothing Future improvement experts, managers and employees in the areas of logistics, suplly chain, planning or other related areas You get to know the theory of Lean Logistics: a) information flow steering from the customer requirement to the placing of orders at suppliers. b) material flow from the supplier to the customer. You experience the implementation of Lean Logistics at BMW in Landshut. Apply what you have learned in the practical workshop and benefit from the exchange of views with experienced experts. EXPERIENCE LEAN EXCELLENCE ON-SITE AT:

10 . 10 LEVEL 2 Lean Administration Practical and professional skills for lean experts in indirect areas Future improvement experts, managers or employees in the areas of purchasing, development, sales or other indirect areas Potential for direct optimisation is realised in the production areas of companies. The approach Lean Administration will show you that huge potential can also be tapped in the indirect areas. You learn step-by-step where to start when reducing waste and lead times, and which pragmatic tools are most successful in increasing productivity and quality. > Awareness: basics / simulation of order processing to analyse and optimise the order cycle / improvement organisation and lean administration concept in businesses > Methodological competence process analysis : process example order processing detailed analysis, process mapping / group work main and part activity overview / development of process guide / interface diagram in the group / swim-lane diagram / value stream analysis example of usage > Methodological competence process optimisation : EMIPS methods general principles for process optimisation / individual work to develop a value stream design > Methodological competence function analysis : order structure analysis transparency regarding internal orders of a function / function analysis determining the potential for optimisation of a function, a department, a team and derivation of measures > Methodological competence regular communication, shop floor management in indirect areas and 5S in the office : consultation rules / management and performance indicators in the office / shop floor management in indirect areas / workplace organisation and 5S in the office > Methodological competence project organisation, planning and implementing change projects : organisation for successful CIP projects in the company / project preparation and planning / group work to develop a project order including phase model You will learn the key tools for analysing and optimising your organisation in the workplace, on a process and divisional level. We provide you with ideas about implementing KPIs and improving your business processes.

11 . 11 LEVEL 2 Lean Purchasing Methods for Lean Purchase Lean Purchasing increases your purchase performance sustainably. In addition to the classical aim of material supply from cost point of view, avoiding wastage and reduction of processing time are focused. The important feature here is the integration of the supplier on a partnership basis. Whereby final costs are reduced and the quality and adherence to delivery dates are secured. Therefore a lean purchase is fundamental for your prospective competitive advantage. Future improvement experts, purchasing manager, supply chain manager, Top Management executives in purchase and supplier management, for instance the Program Manager. > Purchasing strategy: philosophy, characteristics, approach and fields of action / generation of a Lean Purchasing plan that is adapted for the corporate strategy > Purchasing process: designing and optimizing of strategic and operative purchasing-processes > Purchasing organization: strategic and operative requirements / adequate team composition as well as development of the purchase functions with the aid of defined tasks and qualification profiles > Leadership instruments: controlling through scheduled communications and visualization / target-orientated potential achievement through visual purchasing-management > Material procurement: oriented at the requirements of the production / introduction of a universal product group management for evolving differentiation, market-specific supplier strategies incl. fastidious implementation plans and success control > Supplier management: selection of suppliers (inter alia incl. supplier evaluation and negotiation) / preventive risk management / early supplier integration / value stream-focused target cost management (value stream analysis, value engineering, process optimization) Methodology In addition to the theoretical knowledge gained about the Lean Purchase philosophy, the more valuable asset earned by the organization is the implementation of the acquired knowledge in group works, tasks and process-simulation.

12 . 12 LEVEL 3 Advanced Training Enhance your social, leadership and teaching skills Future Lean / CIP trainers who already have workshop experience To bring about sustainable organisational changes, change capabilities are required. Only companies with reserves of such capabilities, are able to sucessfully deliver change initiatives. Do you want to professionally organise your improvement process and develop your own change capabilities? Such initiatives are led by the head of the CIP office, who is responsible for the development of the lean trainers. Lean trainers have cross-functional expertise, they are the sparring partners for management and employees, and in professional terms, are responsible for the lean conformity of the company development. This task calls for individuals with an in-depth knowledge of BestPractices across all company divisions and a readiness to assume a leadership role. Furthermore, lean trainers require strong presentation, methodological and social skills. > Develop technological and methodological competence: fields of action CIP office / presentation of just-in-time (JIT) simulation: exercise learning by teaching > Develop social and management competence: mechanisms of successful qualification / motivation theories, leadership principles and styles / exercise management in practice > Practical workshop (1, on-site): current state analysis of an actual challenge / presentation of interim results to management, feedback / target concept and implementation of emergency measures / creation of CIP protocols, documentation of results / final presentation > Developing communicative competence: convey lean knowledge and analysis methods > Developing leadership competence: exercise mediation of analysis methods and techniques You will further develop your specialist know-how and learn to deal with the difficulties involved in training others. Work with other future trainers on real processes on the shop floor and improve your coaching skills. Ultimately you will be able to put your advanced management, professional and methodological skills to good use at your company. EXPERIENCE LEAN EXCELLENCE ON-SITE AT:

13 . 13 Customer specific training programs IN-HOUSE TRAININGS Our experts come to you: We design tailored trainings to your needs and requirements, from the individual measures to (international) training programs performed hands-on at your company, all with the active involvement of your employees and focussing on your specific issues, topics and processes. This allows you to consolidate the acquired knowledge of your employees with the most effective of all learning methods - direct, accompanied application of the knowledge. The active and short-cycle feedback from our experienced trainers completes the training and ensures the correct application of learned principles, methods and tools. Remembered after 2 weeks... Degree of participation 10% of what is read 20% of what is heard 30% of what is seen Reading Listening Seeing Images Verbal Passive Watching Films 50% of what is heard and seen Watching Performances Watching Demonstrations Visual On site Demonstrations 70% of what is said Discussions Lectures Participation 90% of what you do and say yourself Dramatic Demonstrations Simulation of the exercises Doing Active Direction Application Focus of the Staufen Training Approach Source: Edgar Dale Potential elements of our cooperation: We offer numerous individual trainings in the context of Lean management, process improvement and quality management - professionally, functionally and across the hierarchy. In addition, we offer systematic training programs for your Lean / Continuous Improvement experts and trainers, and your managers. Consulting discussion in your company Analyse the target group Set the training modules Concept confirmation through the training program Carrying out in-house training(s) Evaluating In-house Training(s) Accompanied practical implementation and road map Concept phase Implementation phase

14 Registration and payment. The cost is per person and event date subject to VAT at the prevailing rate. The cost includes conference documents, lunch and refreshments. The amount due for the event must be settled within 14 days of receipt of invoice. Your registration. (level 1 + at least one element of level 2) + LEAN TRAINER (level 1 + at least one element of level 2 + level 3) Registration for stand-alone level 1, 2 or 3 (no certificate included) Booking special. When booking and graduating the Lean Expert version successfully (meaning level 1 + at least one element of level 2), we provide a 5% discount of the regular participant fee. When booking and graduating the Lean Trainer version successfully (meaning level 1 + at least one element of level 2 + level 3), we provide a 10% discount of the regular participant fee. Service provision. Staufen reserves the right to replace advertised speakers and to make alterations to the event programme while adhering to the overall character of the event. Participants shall be notified immediately if the event cannot take place. Bookings may be cancelled free of charge up to 14 days before the event start date; the total amount due shall be payable if bookings are cancelled less than 14 days before the event start date. We gladly accept a replacement participant at no additional cost. 1. Seminar Date 2. Seminar Date 3. Seminar Date 4. Seminar Date Participant Company Jobtitle Street City / Zip Phone Fax Date, Signature REGISTRATION ONLINE: /en/academy REGISTRATION FAX: We are looking forward to assisting you to develop your individual Lean training programme. Janice Köser Academy Management STAUFEN.AG Consulting.Academy.Investment Blumenstraße 5 D Köngen contact@staufen.ag j.koeser@staufen.ag Margret Messerle Academy Organisation m.messerle@staufen.ag