Lean Training

Improvements or changes to systems or methods are carried out by people. 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 thought patterns of management and employees, which have consolidated over many years. Therefore, the importance of employee training is often even greater.

Participation in KPC Kaizen Workshops

Improvement measures in micro-areas, e.g. 5S or improvement of workplace design have little effect on the overall operating result, even if they are pursued over months or years. It is advisable to implement various measures to increase overall efficiency in parallel:

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

Because different areas/departments can and must contribute to the afore-mentioned goals, representatives of these departments are usually also workshop participants:

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

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

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

KPC Lean Basic Training

Basic theoretical knowledge of lean philosophy and lean methods and techniques is important. For this purpose KPC offers its clients 1 to 2-day training courses for groups of 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 theoretical courses over months, we recommend the KPC Lean Basic Training for employees who have already gained practical experience by participating in several KPC Kaizen workshops and have experienced live how quickly changes (process improvements) are possible!