Lean Sigma Training

Central to the Lean philosophy is the need for the educational development of all individuals within an organization. Develop the skills you need...

Productivity's Lean Sigma training has been called the best in the business and for good reason. Our Lean Sigma trainings are more than just awareness. They are designed to ensure a transfer of learning allowing your employees to immediately use the knowledge gained from the training to get results. Our courses break down into three categories:

Lean Executive and Lean Manager Sessions

• Implementing Lean throughout the Value Chain

  In this session learn how to align and integrate Lean practices throughout your enterprise and its constituencies. From upstream supplier relationships through internal processes to downstream customer relationships we’ll explore building a demand-driven value network, and maintaining the metrics necessary for operational and innovation excellence that define a value chain’s performance.
  
  

• Innovation Strategy Development and Deployment

  In this session you will learn a structured Innovation methodology allowing you to build your Innovation capabilities and achieve a new level of top line growth, as well as, learn a set of Innovation principles that you can use in your day-to-day operations to enhance transforming your organization’s processes to a state of operational excellence.
  
  

• Lean Enterprise Overview

  This session will profile a Lean enterprise and explore a process for system-wide waste elimination. From identifying value-add from the customer’s perspective through hands-on execution of the Lean process improvement techniques, participants will practice the principles of planning and implementing a Lean strategy.
  
  

• Lean Leadership

  The overall success of a Lean initiative depends on leadership. In this session we look at the fundamental challenges of leading a Lean transformation, address the most common transformational issues, and discuss the options and alternatives providing remedial corrective-actions, and countermeasures.
  
  

• Lean Manager Awareness Certificate

  The Lean Manager Awareness Certificate is for anyone needing an “entry-level” understanding of the Lean fundamentals. This fully accredited five-day program explores the essentials of Lean planning and implementing a Lean program and then takes a look at the core improvement processes of Value Stream Management, Visual Workplace, Standard Work, Mistake Proofing, and more. Upon completion participants will earn a Certificate of Completion from Productivity Inc. and the Fisher College of Business, The Ohio State University.
  
  

• Lean Manager and Lean Master Certification

  The Lean Certification Programs are fully accredited and designed for middle and top-level executives at any company who seek the essential knowledge necessary to lead, plan, and drive Lean throughout their entire organization. Participants who successfully complete the four-week program, pass the certification exam and have demonstrated successful implementation in their own facility are then certified by Productivity Inc. and the Fisher College of Business, The Ohio State University, as Lean Managers. Those wishing to achieve Lean Master Certification will enter a post-Lean Manager program that is project-oriented and takes ~6 months to complete.

Lean Tools and Techniques

• 3P – Product Design

  In this session, we will explore the creative force of Lean by applying innovative thinking to the design and development of products for the marketplace.
  
  

• 3P – Process Design

  This session, which ranges from the conceptual to the practical, introduces basic principles of Lean process design and shows how those principles can be applied to develop production processes incorporating low-cost, low-waste "Lean machines".
  
  

• Achieving Quick Changeover

  Learn the principles and techniques needed to decrease changeover times and increase inventory turns. This workshop will teach you the changeover methodology that will allow you to gain manufacturing flexibility while increasing your ability to react to customer demands and competitive pressures. This session is comprised of classroom teaching and shop floor hands-on application.
  
  

• Cell Design and One-Piece Flow

  This module will demonstrate how to create cells for one-piece-flow by exploring takt time, jidoka, and the necessary tools of standard work such as standard work sheets, process capacity tables, and standard work combination sheets. Simulation and business case based.
  
  

• Creating and Managing Continuous Flow

  This module will demonstrate how to create flow by exploring the use of heijunka [level sequential flow], takt Time [the pace of the production system], cellular manufacturing, and pull production scheduling techniques such as kanban.
  
  

• Kanban

  Our kanban workshops offer different agendas to accommodate high-volume, low-volume, job shops, and mixed model pull-production environments. These sessions teach the mechanics of kanban, how to perform quantitative analyses, (determining key value stream performance metrics), how to design a mixed model kanban board, and more.
  
  

• Lean Logistics

  This training session explores the part of supply chain management that plans, implements, and controls the efficient, effective forward and reverse flow and storage of goods, services, and related information between the point of origin and the point of consumption in order to meet customer requirements.
  
  

• Lean Supply Chain

  This session teaches new technologies for a Lean supply chain -- a system where inventory, transportation, warehousing, demand information, and sourcing and procurement both up and down the supply chain are integrated almost seamlessly. We'll discuss the coordination and collaboration with channel partners: suppliers, intermediaries, third party service providers, and customers.
  
  

• Leveling

  This session explores several approaches to developing a level schedule at the pace maker process in your value stream.
  
  

• Production Kaizen

  Productivity Inc. first introduced the 5 Day kaizen in the 1980’s. This traditional, high-energy, team-based workshop held in a real-time production environment puts into practice the Lean concepts of takt, flow, and standard work. This workshop is comprised of classroom teaching, simulation and shop-floor application.
  
  

• Manufacturing Measurables

  In this module we will consider measurements such as Dock to Dock, First Time Through, On-Time-Delivery, Overall Equipment Effectiveness, and Build to Schedule.
  
  

• Mistake Proofing

  This module will demonstrate a scientific method to alert, avoid, and control defects and eliminate source errors.
  
  

• Office Kaizen

  Tailored from Productivity’s benchmark 5 Day kaizen introduced in the 1980’s, this traditional, high-energy, team-based workshop held in a real-time office environment, puts into practice the Lean concepts of takt, flow, and standard work. This workshop is comprised of classroom teaching, simulation, and shop-floor application.
  
  

• Project Management

  In this training session we'll explore project management principles, success factors, management guidelines, the easy-to-use practices of monitoring project status, and the aggregate contribution to the company's improvement strategy/initiatives.
  
  

• Standard Work

  In both manufacturing and service operations, standard work is a key element in the elimination of waste and excess inventory and in achieving balanced and synchronized delivery processes. In this session, participants will learn a proven methodology to develop a standard procedure, and then apply document control and visual workplace principles and techniques to train others in their new best practice, or standard work.
  
  

• TPM (Total Productive Maintenance)

  Productivity is uniquely positioned to help you implement Total Productive Maintenance in your facility. From assisting with a complete TPM Roll-out program to providing individual training programs, we have what you need to restore your equipment and keep it running reliably. For complete details on what we have to offer, click here.
  
  

• Value Stream Management

  This module lifts-off the Lean journey by presenting the step-by-step methodology of value stream management. Participants will learn the value stream mapping and story-boarding technique and how to gather all the upstream and downstream information needed to make data driven decisions regarding your Lean activities.
  
  

• Value Stream Mapping for Administrative Processes

  Participants will learn how to apply the value stream mapping technique to administrative processes. Learn the story-boarding technique and how to gather all the upstream and downstream information needed to make data driven decisions regarding your Lean administrative activities.
  
  

• Visual Workplace (5S, Visual Display and Visual Control)

  This kaizen style workshop will teach you the principles and techniques needed to apply 5S and establish visual management systems to improve workplace communication and adherence to standards. This event is comprised of classroom teaching and shop floor hands-on application.

Culture

• 5S and Culture Change

  In this session learn how to use the 5S methodology to not only to clean and organize your workplace, but to empower your people and instill a culture of continuous improvement in your organization.
  
  

• Creating a Lean Culture

  Continuous improvement is the outcome of building dynamic capabilities. In this session learn what it takes and how to create an environment in which employees are engaged, experiment, and where problem solving and improvement are part of daily work.
  
  

• Creating and Managing a High Performance Workplace

  Today, for an organization to truly be competitive, it must find ways of bringing people closer to managing their own work. Doing this within a structured framework focused on clearly defined and communicated business objectives will ensure an employee community aligned with strategic intent. In this session learn what it means to have a high performance workplace and the steps required steps to create a company-wide high-performance environment.
  
  

• Empowering the Workforce

  To be successful in today’s operating environment, leadership must delegate authority, accountability, and freedom to act. This training session provides leaders with a guide to enhance their organizational change process and create a truly empowered workforce.
  
  

• Facilitator Training

  This training session provides the skills necessary for facilitators to foster and manage culture change and prepare them to get and keep teams focused on a process for achieving and sustaining continuous improvement.
  
  

• Supervisor Coaching

  Supervisors play a central role in a Lean transformation. They are the critical link between management and the people in the work place and bridge the gap between the current state culture and the desired one. Through a series of coaching sessions, supervisors will learn ten critical inter-personal performance factors necessary to support a lean transformation process and enhance organizational culture change.
  
  

• Team Dynamics and Conflict Resolution

  In this session participants will discuss their organization’s current approach to managing conflict, discover the eight key elements of an effective conflict utilization process, and take a Conflict Management Survey to help them better understand more about their individual actions and how they behave in conflict situations.

For additional information on these training programs click here