Lean workshops

What:

Implementation of concrete improvement actions by a multi-skills team led by a Lean Expert. Workshops generate the implementation of 30 to 50 actions and also physical changes in the area directly concerned. This leads to metrics improvement up to 30%. The physical changes are visible to improve ergonomics, working conditions, reduce floor space, improve accessibility, reduce downtimes, improve house keeping, ensure greater reliability and machine maintenance, increase productivity.

Objectives:

Enable the implementation of immediate actions.
Raise operators awareness that stretched goals are attainable.
Give operators the opportunity to show what they are really worth.

Added Value:

Tangible results obtained in less than one month by improving quality, safety, productivity and delivery.

How:

A workshop is based on a monthly cycle and lasts 2 to 3 months.

	Workshop preparation	Deployment	Follow-up
Duration	3 to 4 weeks	3 to 5 days	1 month
Who	Consultant + site coordinator and/or manager	Group of 10 participants	Manager with support from the consultant
Content	Select the area to improve, tools, indicators, team Establish a program. Prepare materials and necessary logistics	Facilitate the training-by-doing program Target improvement actions in the workplace Perform as many actions as possible during the workshop Define standards and check them	Monitor the indicators Execute action plan Improve standards and train the teams Ensure new employees are equally trained Deploy in other workshops

Main types of workshops:

Type of workshop	Improvements	Average duration
5S	Improving safety, quality, productivity, lead time and operator motivation	1 month
SMED	Dividing Changeover time by 2	15 days
OEE	Availability improvement from 15 to 20%	3 months
TPM	Dividing Breakdowns and micro-stoppages by 2	3 months
Hoshin	Increasing labour efficiency from 20 to 30%	1 month
Quality: 8D, QRQC	Dividing quality defects by 3 and multiplying customer satisfaction by 3	3 months
Logistics flows	Inventory reduction of 50% in the Supply Chain	2 months
"Milkrun" internal flows	30 to 50% improvements: - WIP reduction - Line parts availability improvements - Handling costs reduction	3 months
Value Stream Mapping/MIFA	Site diagnosis and progress scheduling Site progress workshop organisation Inventory reduction of 50%	3 months
Lean Office	Cutting administrative lead times by 3	1 month