Lean Operations Series



The Lean tools and methodologies, when used effectively, solve real problems and make improvements in the way work is performed at each level in the organization, in each activity, in real time, at the root cause. We follow a ‘learn by doing’ approach so that your employees participate in each and every improvement that is made at every level of the organization, saving money, eliminating waste, and delighting customers.

This training combines lectures, simulations and case studies to help ensure you understand not only what each technique is, but also how to apply it to a real life situation. The schedule of workshops allows you to cover the entire training program in a few weeks.

In order to receive a certificate of successful completion of the entire series, you must pass a short examination given at the end of the series, and submit a report showing the results of an actual lean project completed (project to be agreed upon with instructor). Or you may enroll in individual workshops.

Participants who complete the entire program can take advantage of a FREE 2-hour site visit at your organization from one of our Lean Experts. We will assess your overall operations and provide guidance on how to apply the tools and techniques that you have learned.

Introduction to Lean with Simulation

View Lean as an overall strategy to operating your business, and understand how to introduce the concept of Lean at all levels of the organization. A simulation will point out how the transformation will take place.

Creating a Lean Culture

Learn about 52 validated best practices that define a total lean implementation, including the conditions that must exist in an organization as a prerequisite for effective long term lean results.

Experts in lean say that 80% of lean is adopting a new culture in the organization, and 20% is using the tools of lean. Participants will learn about 52 validated best practices that define a total lean implementation, including the conditions that must exist in an organization as prerequisites for effective long term lean results. Hands-on exercises will help to enhance your understanding of this Lean standard and how to assess an organization.

A3 Problem Solving

Lean is best implemented when the people closest to the work identify and eliminate problems using a structured team process. Learn how to harness the power of A3 problem solving, an extremely simple tool, used by Toyota, to empower every employee to solve problems, using a simple model and reporting method.

5S / Mistake Proofing

Thorough implementation of visual controls and 5S is a requirement of any lean operation. Learn how to develop routines that maintain organization and orderliness - essential to a smooth and efficient flow of activities.

Zero defects cannot be achieved if a process relies on inspections and sorting. Learn how to create processes where the chance of making errors is eliminated using simple error-proofing techniques.

Set Up Reduction / Total Productive Maintenance

True flexibility means being able to change over at a moments notice without adding costs. Learn how to reduce lot sizes by reducing set up time.

Total Productive Maintenance (TPM) seeks to maximize equipment effectiveness by applying aspects of periodic, preventive, and autonomous maintenance. Lean Maintenance focuses on optimization of the maintenance process, is lead by maintenance managers, and is implemented by the maintenance employees. Lean Maintenance strategies can be applied today to provide immediate improvements and return on investment.

Value Stream Mapping / Running a Rapid Improvement Event

The starting point of the lean journey, creating the current state value stream map helps you "see" where to focus your attention to ensure improvement activities truly create continuous flow from supplier to customer.

A Lean Event is a way to accelerate the lean implementation process by using a focused group of people on a team to improve on cost, time and space for a particular product or process, with a one-week deadline. Learn how to effectively plan and facilitate Kaizen events for your company.

Please see the workshop schedule for course details and all current workshop dates.



For more information, contact us at: (630) 505-0500 or info@illinoisbis.org.