The World Class Organization
Operational excellence is a comprehensive approach to eliminating all forms of waste and defects from your business in order to maximize the value to customers and shareholders. Typically, organizations that apply OpEx principles enjoy higher profits, improved quality, higher on-time delivery (OTD), shorter turnaround times, increased customer satisfaction, employee engagement, and market share.
This course will teach your participants effective training on how to initiate and sustain a strategy in your business. All the materials and activities in this workshop are designed to help you transform your organization into a world class enterprise. VDS has courses specifically for all Industries, i.e. Manufacturing, Aftermarket, Insurance, Services, Retail, Oil & Gas, Pharma, Life Sciences, Agriculture, Mining, Construction, Field Service, Chemicals, Health Care, etc.
Cellular Design for OEM, Office, and MRO
Redesigning work spaces based on part families and work content in order to meet Takt time requirements. Learn the critical roll of equipment and personnel location, and material and tool presentation in workplace efficiency and flexibility. Learn to maximize floor space utilization.
Root Cause Analysis and Mistake Proofing
A three step approach to effectively identify the root cause of problems and eliminate it to prevent reoccurrence. Learn to design error prevention into the process or product to achieve zero defects.
Value Stream Process Management
More than just mapping. Using VDS' data-based approach, participants will learn to define and choose the right product family to improve. Learn to see the complete process flow and quickly identify sources of waste. Available for manufacturing, MRO, and office (service) environments.
Shop Floor Management
Learn who to utilize Leadership Standard Work, GEMBA (go to where the work happens), Reflection Meetings (how to take action and resolve problems as they arise with data), Andon (a system to identify abnormalities with an escalation process), Accountability Process (how to assign ownership and responsibility at all levels), mentorship (grooming our workforce to learn and take higher roles of responsibility)
Train the Trainer
Develop your own internal training and facilitation force to drive change and perpetuate the benefits of Lean in your organization. Further develop future and current leaders of your organization through practical Lean implementation experience.
Business Process Kaizen (BPK)
Business process kaizen is a systematic methodology developed to help an organization make significant advances in the way its business process operate. It attacks the heart of office/administrative problems by focusing on eliminating waste and bureaucracy. It provides a system that will aid an organization in simplifying and streamlining its operations, while ensuring that both internal and external customers receive surprisingly good output.
Ineffective business processes are costly. Between 40% to 70% of the administrative (business process) efforts adds no value. Eliminating business process errors and office bureaucracy through business process kaizen methodology can cut overhead costs by as much as 50%, make an organization a leader in its field, and greatly improve its customers’ perceptions of the organization.
3P Production Preparation Process
One of the most transformative tools in the Lean methodology, 3P goes beyond gradual improvements, instead aiming for out-of-the-box changes with a big impact.
3P stands for “production, preparation, process” and describes the first in a series of three Lean design stages. Lean design also includes rapid idea testing and embedding Lean tools and principles into work-space design and internal processes.
This Lean 3P training is designed for learners who already have experience with Lean practices like Kaizen, Practical Problem Solving, and 5S.
VDS’s Co-Learning Partner Program is for leaders looking to transform their enterprise and contribute to the Lean thinking and practice body of knowledge. Together, you will solve your business problems and achieve breakthrough performance.
“Co-Learning” means everyone learns from each other. Partners develop their lean thinking and capabilities as VDS coaches guide them through addressing a business problem. Partners also learn from one another when VDS brings them together to share their lean experiences. This approach enables VDS to discover new ways to advance lean thinking and practice.
Introduction to Lean Transformations
Understanding our fundamental concepts of value, waste, and flow. Learn to determine Takt Time and implement Pull systems. Become familiar with the origin of Lean Thinking. Learn to identify the 8 wastes and how to eliminate them.
Hoshin Kanri – Policy Deployment
The discipline of Hoshin Kanri is intended to help an organization focus on a shared goal, communicate that goal to all leaders, involve all leaders in planning to achieve the goal, and hold participants accountable for achieving their part of the plan.
Knowledge and/ or skills attendees will gain:
- Utilizing Hoshin Kanri as a strategic planning tool to revisit and realign your company’s Vision, Mission and Core Values
- Revisit and redefine your current strategic plan through the utilization of Hoshin-Kanri tools
- How Lean Leadership Behaviors impact the cultural success of Hoshin Kanri
- Establishing high-level organizational roles and responsibilities to successfully deploy your strategic plan (Policy Deployment)
- Utilizing Hoshin planning tools to review current business activities and business environment
- Validating and creating key measures for tracking performance against Hoshin Kanri Strategic Plan
Total Preventative Maintenance (TPM)
Learn to reduce costs and increase overall equipment effectiveness by combining preventive and predictive maintenance with increased operator responsibility. Learn to design a comprehensive maintenance system for the life cycle of your equipment. Become familiar with the 6 Big Losses and the TPM activities to eliminate them.
6S for Flow
Create positive customer impressions, increase employee morale, safety, and efficiency through workplace organization. Learn to design and implement a self-sustaining 6S program that can be the foundation for World Class performance.
Conducting Market Feedback Analysis
Learn to "really" listen to the voice of the customer (VOC), both internal and external. Achieve a better understanding of their requirements and expectations. Learn how to use this information to guide your Lean initiatives and incorporate it in your strategy.
Leader Standard Work
Understand how to manage your teams at an Enterprise, Site Cell, and Process level by engaging in Leader Standard Work following the Lean Principles of:
GEMBA - is the Japanese term for “actual place,” often used for the shop floor or any place where value-creating work occurs.
Reflection Meetings - A meeting reflection is a special session aimed to help team members learn together by reflecting on a recent project or experience as they share it with others. It's an easy and informal way of nurturing creativity and sharing knowledge by discussing topics outside of their common day-to-day tasks.
Andon - A signal that a process failed and when it does it triggers an escalation process to correct.
Accountability Process - Each team member has a role and responsibility.
Mentorship - learning a skill set outside of your normal responsibilities through guidance provided by a mentor.
Lean Leader Program Structure
This two-part program first helps leaders learn the A3 problem-solving method, or enhance their A3 capability, by first immersing them in an A3 problem-solving experience that addresses a significant business issue.
• Round 1: Leader as Problem-Solver – Leaders first learn the A3 problem-solving method (or enhance their capability), by immersing themselves in an A3 problem-solving experience that addresses a meaningful business issue aligned with their organizational objectives.
• Round 2: Leader as Coach – Leaders learn effective ways to coach their team members in the A3 methodology by guiding direct reports through a similarly immersive A3 problem-solving experience.
The program is a blend of remote learning sessions, hands-on practice applied to your own problem, and in-person 1:1 coaching as you develop your problem-solving A3.