Lean Training

Employees are on the front line when it comes to changing systems/methods or making improvements. In our experience, the following ratio should be taken into account:

  • Methodological/systemic changes: 50 %
  • Employee training: 50 %
Processes and activities reflect the current corporate culture and ingrained thought patterns of management and employees, which have consolidated over many years. This makes it even more important to effectively train your employees.

Participation in KPC Lean/Kaizen Workshops

Improvement measures in micro-areas, e.g. 5S or improving workplace designs have little effect on the overall operating result, even when pursued over months or years! Therefore it is advisable to implement various measures in parallel to achieve a balanced increase in overall efficiency:

  1. Reduce production lead time
  2. Reduce inventory (raw material, semi-finished products, finished products)
  3. Improve delivery reliability
  4. Quality work
  5. Reduce lead time in order processing
  6. Reduce lead time in R&D and design processes
  7. Increase space efficiency
  8. Increase resource productivity

Because different areas/departments can and must contribute to the afore-mentioned goals, representatives of these departments should also participate in the workshops:

  • Production planning
  •  Production
  •   Purchasing
  •   Storage
  •   R&D and construction
  •   Human Resource
  •   Distribution
  •   Order management
  •   IT

As part of the current-state analysis we draw up a workshop plan (= curriculum) for 12 months in advance. It goes without saying that the best learning effect can be achieved by participating in Kaizen/Lean workshops. In particular, we teach:

  • Overall efficiency increase has higher priority than efficiency increase in micro areas
  • To achieve a goal, you have to question and improve many standards in different departments
  • Interdepartmental cooperation is essential

KPC Lean Basic Training

A basic theoretical knowledge of lean philosophy and lean methods and techniques is important. For this purpose KPC offers its clients 1 or 2-day training courses for employees.

The seminar contents are:

  • Lean philosophy according to the Toyota Production System
  • Kaizen Mind Setting
  • Cycle time production system
  • Process Synchronization
  • Pull principle
  • 5S
  • Standard work
  • Lean production planning
  • Kanban system
  • Lean factory layout
  • Lean supply chain management
  • Lean cost to design 
  • TQM Total Quality Management
  • TPM Total Productive Maintenance
  • Lean visual management system
  • Lean communication system: sales, planning, design, purchasing, warehouse, production

Instead of participating in months of theoretical courses, we recommend KPC Lean Basic Training for employees who have already participated in previous KPC Lean/Kaizen workshops and know how quickly changes (process improvements) can be achieved!