2011 TBM LeanSigma Institute Catalog

LeanSigma® Training and Development

Worldwide Training Catalog

Certification – Seminars – Conferences – Online Learning – Events – Customized Training

Table of Contents Comprehensive Training Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Certification Lean Certification Kaizen Facilitator and Lean Certification Program Leader (LC) . . . . . . . . . . . . . . . 2-3

LeanSigma Green Belt (LSGB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 LeanSigma Black Belt (LSBB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Seminars CEO Boot Camp (CEO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Creating a Continuous Improvement Office (CCIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Design for LeanSigma (DLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Executive Round Table (ERT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 High-Impact Maintenance Manager (HIMM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Kaizen Breakthrough Experience (KBE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Kaizen Instructor Training – Business Process (KIT-BP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Kaizen Instructor Training – Manufacturing Operations (KIT-MO) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lean Management Accounting (LMA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 LeanSigma for Process Industries (LSPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Lean Tool Kit (LTK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Leveraging Lean for Growth (LLG). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Managing for Daily Improvement (MDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Quest for the Perfect Engine (QPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Quest for the Perfect Engine – Garment Industry (QPEG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Sustaining Lean Results (SLR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Conferences LeanSigma Global Summit (LSGS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Lean Excellence Conference (LEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Online Learning Essential Lean Learning (ELL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25 Our Team . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 About the TBM LeanSigma® Institute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

www.tbmcg.com | 800.438.5535

Comprehensive Training Solutions Certification Develop skill mastery through our experiential, hands-on courses for Lean Certification – Kaizen Facilitator or Program Leader, LeanSigma Green Belt or LeanSigma Black Belt. These courses are appropriate for organizations who wish to create in-house experts capable of supporting and driving operational excellence program objectives. Our certification training is available in a public classroom setting at our training facility in Durham, NC or at our regional office locations throughout the world.

Seminars Choose from a broad range of training seminars to advance critical knowledge required to support your lean transformation efforts. Most courses are available in a public classroom setting at our training facility in Durham, NC or at our regional office locations throughout the world. Be sure to ask if you are interested in on-site delivery for groups of ten or more or if you require a more customized workshop tailored to the specific needs of your organization.

Conferences Every year, the LeanSigma Institute hosts various events that encourage benchmarking, networking and sharing of experiential learning. Our conferences include a combination of case presentations, panel discussions, keynote speakers and intimate, roundtable working sessions to develop solutions for today’s current issues.

Online Learning If self-paced, web-based learning is what you need, consider our online learning curriculum. The Essential Lean Learning curriculum is designed by TBM lean practitioners and based upon our experience developing and teaching LeanSigma methodologies over the past twenty years. Designed to ensure understanding, application and retention of basic lean concepts. Visit www.tbmcg.com/learnonline for a live demo.

Events Throughout the year, TBM presents at numerous industry conferences and expositions and hosts several online webinars. You may register for upcoming events, learn about future speaking engagements, or view archived events.

Visit www.tbmcg.com/events to learn more.

Customized Training Customers rely on the LeanSigma Institute to develop a comprehensive, customized lean training program that meets their requirements for developing resources capable of delivering growth, profitability, flexibility and responsiveness.

Organizations with heavy Six Sigma focus often seek our assistance integrating a lean perspective and transitioning continuous improvement activities toward customer-facing enhancements that drive responsiveness and flexibility and –most importantly – support growth initiatives.

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TBM LeanSigma Institute

www.tbmcg.com | 800.438.5535

TBM Lean Certification Lead the Way Comprehensive certification training for companies that wish to develop in-house capabilities to accelerate their lean deployment.

Two Lean Certification Programs TBM has created two lean certification programs for companies which wish to develop in-house capabilities to accelerate their lean deployment. All coursework is delivered through a blend of online learning, classroom training, skills demonstration, and interactive mentoring.

Kaizen Facilitator Program Leader

Pricing

Lean Certification – Kaizen Facilitator Learn to Support Effective Kaizen Events Understand essential lean tools and how they are used to drive results. Includes selfpaced online learning and three weeks of hands-on training. Candidates will be mentored by a TBM Lean Master and will graduate with hands-on experience and knowledge in the following critical areas: • Knowledge of lean strategies, tools, and methods which include the fundamentals of the Toyota Production System, including takt, flow, pull, and standard operations • Skills required to support effective kaizen events and conduct basic training for kaizen teams • Participation in a kaizen event on the shop floor – or in a business process at a manufacturing facility • Development of a current and future value stream map for a facility or product family

Lean Certification – Program Leader Learn to Lead a Lean Deployment Candidates complete all coursework from the Kaizen Facilitator course in addition to learning how to create and manage an effective lean office and how to audit, report, and sustain results of a lean program. Includes self-paced online learning and five weeks of hands-on training. Candidates will be mentored by a TBM Lean Master and will graduate with hands-on experience and knowledge in the following critical areas: • Knowledge of lean strategies, tools, and methods including some of the fundamentals of the Toyota Production System: takt, flow, pull, and standard operations

TBM Lean Certification Courses Kaizen Facilitator $8,500 USD Program Leader $12,500 USD • Students must be willing to travel, have access to the Internet and Microsoft® applications including Visio®, PowerPoint® and Excel®.

We recommend students have access to a laptop computer to allow them to work on certification objectives during classroom events.

• TBM clients who have completed portions of the curriculum may qualify for learning credits at the discretion of the program director.

• TBM will also modify the course and create a customized Lean Certification curriculum for companies that prefer to send a dedicated team of students in a single program.

• No discounts apply.

• Skills required to support effective kaizen events and conduct basic training for kaizen teams • Participation in a kaizen event on the shop floor – or in a business process at a manufacturing facility • Development of a current and future value stream map for a facility or product family • How to create, manage, communicate, and promote an effective continuous improvement office • How to write a project charter, develop scope, and create objectives for a kaizen event • How to align operations metrics with financial performance • How to audit, report, and sustain results from your lean deployment 2

TBM LeanSigma Institute

LC

Lean Certification Certification

Kaizen Facilitator - www.tbmcg.com/kf Program Leader - www.tbmcg.com/pl

800.438.5535

TBM Lean Certification (con’t) Lead the Way

TBM Lean Certification Program Choices Time Commitment

Description

Kaizen Facilitator

Program Leader

Self-paced online learning

Modules include: Introduction to lean; Waste elimination; Just-intime principles of takt, flow and pull systems; Quality and productivity improvements through Jidoka; Production Smoothing, Standard Work, Standard Operations; 5S and the visual workplace; Value Chain Mapping, LeanSigma Implementation; and Roles in a lean deployment. Candidates must pass a final exam upon completion off all modules.

Lean Tool Kit Workshop*

5 Days

Learn how lean tools are applied to transform your organization to deliver improved operational results. Through the use of a factory simulation, students will be able to apply what they have learned.

Kaizen Breakthrough Experience

5 Days

Hands-on participation on a kaizen team at a TBM client site.

Participants are divided into teams that are led by a TBM Lean Master.

Team members are assigned roles; the event is planned, executed and evaluated.

4 Days

Train-the-trainer workshop designed to teach participants how to deliver TBM’s one-day lean training, an essential component of facilitating kaizen events. Participants hone public speaking skills and learn how to address the tough questions from individuals that will participate in or be impacted by a kaizen event.

4 Days

Learn the strategies, tools and skills required to set up and administer an effective continuous improvement office. Topics include: how to communicate and promote a lean program, write charter statements, align operational metrics with financial objectives, assess your lean progression, form and manage a lean steering committee, and share best practices across the organization, (We recommend that Program Leader candidates complete this course before taking Kaizen Instructor Training)

5 Days

Participants learn to audit, report, and sustain kaizen results. Concepts covered include: personality assessment and how to work with different types of people, cultural change and how to deal with resistance, performance measurement, layered audits, and problem solving tools.

On-going

Each participant is assigned a TBM Lean Mentor to guide them through the certification process. Homework, quizzes, a kaizen report-out, and a final exam are all part of the certification program.

Learning

Essential Lean Learning – Online training and Exam*

Kaizen Instructor Training

Creating a Continuous Improvement Office

Sustaining Lean Results Mentor, Homework, Quizzes, Kaizen Event report-out and Final Exam

* Candidates MUST complete the online training, Lean Tool Kit course and exam before progressing to other modules of Lean Certification.

“By becoming proficient and certified in lean, we increased the speed, understanding, and transition of lean concepts within our company. Intensive coaching and mentoring is imperative to change the mindset through the entire organization. I rely on our TBM mentor to help make quantum leaps in the experience. He challenges our thinking while offering perspectives on what could be better.”

Michael Gerster, President WIKA Instrument Corporation 3

TBM LeanSigma Institute

LC

Lean Certification Certification

Kaizen Facilitator - www.tbmcg.com/kf Program Leader - www.tbmcg.com/pl

800.438.5535

LeanSigma Green Belt Certification Green Belt Certification with a Lean Twist Hands-on, experiential training for operations professionals who need to combine lean and Six Sigma tools to rapidly implement high-impact business improvements. Provides candidates with LeanSigma principles, kaizen methodology and Six Sigma statistical problem-solving tools to create a faster approach to identifying and correcting problems.

Ideal Attendees Management and operations team members who wish to learn and use lean and Six Sigma tools to solve business problems using all the tools of LeanSigma

Three Non-Consecutive Week Agenda Week One • Classroom training: Define/Measure/Analyze phase

Key Learning • Three weeks of training and skill transfer • LeanSigma, the proven methodology which combines lean and Six Sigma into a single, coordinated initiative • DMAIC structured problem solving model • Six Sigma statistical and analytical tools • Sigma Kaizen methodology and how to use it to reduce project time from six months or more – to six weeks or less • Leadership training on how to lead project teams within your area of responsibility to rapidly implement high-impact business improvement

Week Two • Sigma kaizen event: Measure/Analyze on-site Week Three • Classroom training: Analyze/Improve/Control phase

Tools Learned • Sigma Kaizen Methodology • DMAIC

Pricing • Individual: $7,200 • No discounts apply to this certification course

“This program has made a huge difference in the speed and capabilities of our new Green Belts.”

Tom Barrett, Director of Continuous Improvement Landscape Structures, Inc.

LeanSigma Green Belt certification is not a prerequisite for attending LeanSigma Black Belt.

TBM Green Belt Training Strategy Define Measure/Analyze (one week classroom)

Analyze/Improve Control (one week classroom)

Three-week Interim

Four-week Interim Sigma Kaizen Measure/Analyze Event (one week led by Master Black Belt)

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TBM LeanSigma Institute

LSGB

LeanSigma Green Belt Certification Certification

www.tbmcg.com/lsgb | 800.438.5535

LeanSigma Black Belt Certification Black Belt Certification with a Lean Twist Multi-week, experiential training for full-time, continuous improvement and quality team members. Teaches candidates how to lead Sigma Kaizen events and how to use kaizen to complete black belt projects in six weeks versus a typical six months. The curriculum includes value-stream analysis and Six Sigma problem-solving tools.

Ideal Attendees

Four Non-Consecutive Week Agenda

Full-time Continuous Improvement and Quality team members

Week One

Key Learning

• Classroom training: Define/Measure/Analyze phase

• Four weeks of training and skill transfer • LeanSigma, the proven methodology which combines lean and Six Sigma into a single, coordinated initiative

Week Two • Sigma kaizen event: Measure/Analyze on-site

• Tools and techniques to accurately assess Voice of the Customer • The rationale and process for project identification and selection • Key Lean Manufacturing principles, including Kaizen and Value Stream Analysis

Week Three • Classroom training: Analyze/Improve/Control phase

• Advanced Six Sigma statistical problem-solving tools including hypothesis testing and design of experiments • Sigma Kaizen methodology and how to use it to reduce Black Belt project time from six months or more – to six weeks or less

Week Four • Classroom training: Advanced LeanSigma skills

• Leadership training on how to lead project teams to rapidly implement highimpact business improvement • Methods to engage executive management and to ensure effective governance of your LeanSigma initiative

Tools Learned • • • • •

Voice of Customer analysis Value Chain analysis Sigma Kaizen Methodology Design of Experiments DMAIC

“A ‘turbocharged’ Black Belt program, with more tools to achieve maximum improvement and quality levels in far less time.”

Pricing

TBM Black Belt Training Strategy

• Individual: $9,600 • No discounts apply to this certification course

LeanSigma Green Belt certification is not a prerequisite for attending LeanSigma Black Belt.

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Frank Bailey, Director, Global Continuous Improvement Entegris, Inc.

Define Measure/Analyze (one week classroom)

Three-week Interim

Sigma Kaizen Measure/Analyze Event (one week led by Master Black Belt)

Four-week Interim

Advanced LeanSigma Skills (one week classroom)

Three-week Interim Analyze/Improve Control (one week classroom)

TBM LeanSigma Institute

LSBB

LeanSigma Black Belt Certification Certification

www.tbmcg.com/lsbb | 800.438.5535

CEO Boot Camp CEOs Learning Lean from CEOs An intimate, one-on-one opportunity to meet and learn from leading CEO practitioners who aggressively leverage lean as a tool for market dominance.

Ideal Attendees • Chief Executive Officers/Presidents • Chief Operating Officers • Chief Financial Officers • Senior-level staff members who report directly to executive management

Two-and-a-Half Day Agenda Day One • • • •

Lean transformation roadmap Host presentation Plant tour Cocktails and dinner with speaker

Overview TBM Founder and CEO, Anand Sharma, personally facilitates this event every year. CEO Boot Camp is a unique opportunity for executives to interact closely, one-on-one with other executives who aggressively leverage operational excellence as a tool for market dominance. Meet directly with the executive leadership at host companies to discuss how they are successfully implementing and achieving their strategic objectives. Immerse yourself for a brief period of time and see what each company has accomplished, understand how they have overcome hurdles, and learn first-hand how they achieved lasting culture transformation.

Key Learning • See what these senior executives have built through their lean transformations • Understand how they have overcome hurdles and removed obstacles to ensure lean success, differentiation, innovation, incremental sales and earnings growth

Day Two • • • • •

Host presentation Plant tour Host presentation Plant tour Cocktails and dinner with speaker

Day Three • • • •

Host presentation Plant tour Leadership assessment Closing remarks

• Understand first-hand what they had to do to create culture change • Get a sense of what it takes to drive a lean transformation • Spend quality time with lean CEOs, during which you can observe and learn from their leadership styles • Leave energized and ready to launch a lean journey on your own

Pricing • See website for pricing. Agenda and pricing vary based upon location and number of host companies. See specific details at www.tbmcg.com/ceo.

“A first class event with excellent discussion among peers.”

Bill Higgins, Executive Vice President and Chief Operating Officer Circor International, Inc.

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TBM LeanSigma Institute

CEO

CEO Boot Camp Seminar

www.tbmcg.com/ceo | 800.438.5535

Creating a Continuous Improvement Office Run Your Continuous Improvement Office the Right Way Provides the strategies, tools and skills required to quickly establish a highly-effective continuous improvement office, confidently chart your path of lean improvement, maintain and build momentum and achieve dramatic, sustainable results.

Ideal Attendees • Operations management professionals • General managers • Plant managers • Lean or kaizen promotion office managers and team members

Four-Day Agenda Day One • Introductions • Continuous improvement office organization, roles and activities • Communication and promotion

Key Learning • Build current and future state value chain maps • Define lean performance measures, targets and tracking strategies • Build and maintain momentum and enthusiasm

Day Two • Writing charter statements • Continuous improvement benefits and calculating ROI

• Drive cultural change within your organization • Learn a system for targeting, planning and executing kaizen events • Define the standard work for leaders and managers

Tools Learned • • • • •

Value chain mapping Continuous improvement office organization Cultural transformation techniques Performance measurement Lean progression rating

Day Three • Steering committee • Event planning and preparation Day Four • Lean progression rating • Sharing best practices • Review of the week

Pricing • Individual: $3,250 • Group: $2,750 each, for three or more people from the same company

“This workshop was exactly what I needed to help me be an effective continuous improvement manager.”

Les Webb, Kaizen Promotion Office/Inside Sales Securitron

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TBM LeanSigma Institute

CCIO

Creating a Continuous Improvement Office Seminar

www.tbmcg.com/ccio | 800.438.5535

Design for LeanSigma Lean Product Development and Launch Experience this effective approach to new product development, production process design and implementation within a lean framework. Learn how to consistently launch innovative products significantly faster than your competition.

Ideal Attendees • • • • • • •

Design engineers Manufacturing engineers Product and marketing managers Operations managers Quality managers Continuous improvement managers Others in the design and production process

Key Learning • How to use Voice of Customer (VOC) to understand true customer needs and translate them into critical product requirements • Maximize quality and production flexibility to easily adapt to variations in customer demand • Dramatically reduce your development costs and be consistently first to market with innovative, high-appeal products • Participate in a hands-on simulation and learn how to apply lean growth tools to streamline the product development process

Tools Learned • • • • •

Voice of Customer (VOC) House of Quality Managed Creativity for Concept Development Design for Manufacture and Assembly Production Preparation Process (Seven Alternatives, Simulation, and Process-at-a-Glance)

Pricing

Five-Day Agenda Day One • • • •

Introductions and expectations LeanSigma transformation Design for LeanSigma (DLS) overview DLS (Phase-Gate) process and kaizen interventions

Day Two • Voice of Customer (VOC) • House of Quality (HOQ) • Design for Manufacture and Assembly (DFMA) Day Three • Concept development and managed creativity • Design for Six Sigma quality tools Day Four • Lean production system • Production preparation principles • Production preparation process Day Five • Production preparation process (con’t) • Exercise: “Taking it Home” • Conclusion and closing discussions

• Individual: $3,450 • Group: $2,950 each, for three or more people from the same company

“The first product we developed with this process was in the market in one-third of our normal time. The design is unlike any other comparable product with benefits our customers really wanted. Our biggest competitor in that market already wants to license it from us.”

Timothy H. Powers, Chairman and CEO Hubbell Incorporated

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TBM LeanSigma Institute

DLS

Design for LeanSigma Seminar

www.tbmcg.com/dls | 800.438.5535

Executive Roundtable Leveraging Operational Excellence as a Strategic Platform for Growth Is your company innovative, agile and positioned for growth in a fiercely complex, global economy? Are the improvements in your operational excellence program aligned to clearly deliver meaningful, measurable value? Do they advance the company’s strategic vision?

If you are tempted to answer “no” to any of these questions, you are not alone.

Ideal Attendees • Executive team members and senior leadership from operations and continuous improvement • Organizations who have implemented continuous improvement programs yet question the alignment of value creation resulting from its efforts • Executives of organizations preparing to launch a continuous improvement program who want to understand the management process and systems required to succeed

The Challenge: Out-Performing the Competition • Recent studies reveal that CEOs identify three key success drivers: operational excellence, extending business to new customers and markets, and creating business models capable of delivering growth. Similar research also indicates that executives are concerned about obstacles such as risk-averse cultures, lengthy product development times and inadequate measurement systems.

• While more than 70 percent of manufacturers have implemented a continuous improvement (CI) program, over 40 percent of executives say their CI initiatives are failing to achieve operational and strategic objectives.

By ensuring their CI programs are meticulously and rapidly executed, TBM has helped companies realize sustainable top-line growth and higher profitability.

• This 1.5 day executive roundtable is designed for executives who wish to experience first-hand how manufacturers are leveraging lean as a strategic weapon for growth.

This Roundtable can help you: • Understand how to effectively marry continuous improvement initiatives to the strategic vision

One-and-a-Half Day Agenda Day One 2:00 – 5:00 pm • Marrying improvement activities to the strategic vision • Aligning business results to operational excellence • Creating a Business Management System grounded by process excellence • Extending operational excellence beyond manufacturing • Strategy Deployment process overview and best practices • Business performance metrics and tracking • Case examples & interactive discussion 6:00 – 8:30 pm • Dinner Day Two Morning • Presentation and overview from a TBM Client, a tour of the facility and an execuitve Q&A session. Lunch provided.

Afternoon • Executive Roundtable discussion and adjourn in time for late afternoon flights.

• Benchmark your operational excellence program to best-in-class results • Discuss experiences and strategies with other lean-focused executives in a small-group setting

Pricing • Individual: $850 • For teams of two or more: $650 each

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TBM LeanSigma Institute

ERT

Executive Roundtable Seminar

www.tbmcg.com/ert | 800.438.5535

High-Impact Maintenance Manager Essential Training and Development for the Proactive Maintenance Manager Creating, implementing and sustaining a world class maintenance organization that proactively achieves up-time excellence.

Ideal Attendees • • • •

Maintenance managers and supervisors Operations management Plant managers Continuous improvement leaders

Key Learning Learn about best practices and obtain helpful tools to create a world class maintenance organization: • Transition the maintenance organization from a reactionary role of “equipment repair” to a proactive partner in uptime excellence • Create a maintenance vision and the strategy to accomplish your objectives • Develop and implement an effective process for evaluating your production and facility equipment • Develop an effective capital plan for equipment replacement and upgrading.

• Perform a maintenance skills matrix evaluation, identify and provide training for immediate results, and hire people with the correct skills • Locate waste in your current maintenance process and develop a future state maintenance map of your maintenance organization • Understand the root causes of equipment failures and how to stabilize equipment failure rates • Evaluate your lubrication effectiveness and develop a plan of lubrication excellence

Bottom Line Benefits • • • •

Reduce equipment downtime Improve equipment reliability and output (OEE) Improve OSHA compliance/Reduce injury rates Reduce scrap rates, maintenance and energy consumption costs

Pricing

Three-Day Agenda Day One • Identify your maintenance vision • Identify and discuss your critical pieces of equipment • Maintenance skills inventory and assessment • Maintenance mapping – how to locate waste in your current maintenance process Day Two • Best practices for approaching zero equipment stoppages – Why equipment fails – Four-phase approach to zero stoppages – Overall equipment effectiveness case studies • How to develop lubrication excellence • How to evaluate your lubrication strategy Day Three • Best practices for performing preventive maintenance – Developing condition-based preventive maintenance – Preventive optimization and predictive maintenance • Planning & scheduling • Barriers to world class maintenance • Key performance measurements • Develop a going-forward strategy

• Individual: $2,700 • $2,300 per person for groups of three or more

10 TBM LeanSigma Institute

HIMM

High-Impact Maintenance Manager Seminar

www.tbmcg.com/himm | 800.438.5535

Kaizen Breakthrough Experience Participate in a Live Kaizen Event Experience the dramatic bottom-line improvement and efficiency you can quickly achieve and sustain as your Kaizen team implements lean tools on the factory floor or in a business process support function.

Ideal Attendees

Five-Day Agenda

• Chief Executive Officers/Presidents, Chief Operating Officers, Vice Presidents, Directors • General Managers, Department Managers, Plant Managers • Operations and continuous improvement staff • Team members from various departments including: Kaizen Promotion Office, Quality, Materials, Human Resources, Engineering • Administrative staff from various departments including: Accounting, Marketing, Sales, Customer Service

Key Learning • Experience the key concepts, tools, and techniques used during a kaizen week • Participate on a dedicated kaizen team and drive immediate improvement • Learn to identify waste and eliminate non-value-added activities • Achieve typical kaizen event results: – Shopfloor Operations: Inventory reductions of 90%+, productivity increases of 25-50%, product lead times reduced from weeks to hours, elimination of safety hazards, improved 5S scores – Business Process: Backlog reductions of 90%+, cycle-times reduced from weeks to days, productivity increases 25-50%, customers service levels increased to 99%+ • Get excited about kaizen and leave energized to apply what you have learned

Tools Learned • • • •

Kaizen methodology Lean Production System Standard Operations Progressive 5S

• • • •

Visual Workplace Management Assembly Line Design Setup Reduction Other Advanced Techniques

Day One • Overview of the lean production system • Standard operations, elements, and tools • More advanced tools depending on project chosen • Host company welcome presentation • Team leaders’ briefing Day Two • Host company plant tour • Kaizen team activities – Time studies – Workplace improvement discussions – Hands-on workplace improvement Day Three • Kaizen team activities – Continue hands-on workplace improvements – Test workplace improvements – Re-time cycle times Day Four • Kaizen team activities – Refine improvements – Establish and document standard work – Run improvements – Re-time and establish new cycle times – Prepare presentation Day Five • Team presentations and report-out

Pricing • Individual: $3,450 • Group: $2,950 each, for three or more people from the same company

“On the way home, we were totally fired up and could not wait to get back and start implementing what we had seen, done, and learned during that week.”

Michael Gerster, President WIKA Instruments Corporation

11 TBM LeanSigma Institute

KBE

Kaizen Breakthrough Experience Seminar

www.tbmcg.com/kbe | 800.438.5535

Kaizen Instructor Training - Business Process Comprehensive Train the Trainer Program Critical kaizen instructor training that sets the foundation for dramatic improvement and successful culture change at the start of each business process kaizen event. Learn to conduct day-one training of lean concepts and build team awareness and support at the beginning of each kaizen event.

Ideal Attendees • • • •

Four-Day Agenda

Kaizen promotion office managers Continuous improvement managers Engineers Administrative office managers

Day One • • • • •

Key Learning • Lean and kaizen training content required to build team awareness and support at the start of each business process kaizen event • Advanced instructor presentation, training, and teaching skills – for maximum impact • Preparation techniques for business process kaizen events to ensure peak results • In-depth familiarity with all training materials • Interactive simulation exercises and anecdotes to reinforce key concepts • Responses and role plays for questions your instructors will commonly receive

Tools Learned • “Train the trainer” techniques

Pricing • Individual: $3,250 • Group: $2,750 each, for three or more people from the same company

Prerequisites Attendees without a signed material licensing agreement will be charged an additional $500 for access to licensed training materials. The minimum experience level required is four business process kaizen events. In order to maintain a consistent level of experience among course attendees, we will conduct a brief interview to determine your level of lean experience before admittance is approved.

Introductions and overview How to be an effective trainer and facilitator Exercise 1: team building Lean fundamentals, concepts and principles Five minute presentations

Day Two • Business process characteristics • Waste identification and elimination • Exercise 2: team building • 5S in the office • Round one presentations Day Three • Standard operations review • Kaizen breakthrough methodology review • Simulation 1: business process • Round two presentations • Business process improvement tools review • Exercise 3: team building Day Four • Presentation video taping • Business process cost savings • Use of memory aides • Case studies • Key learnings

“A very enjoyable and informative week! I feel more passionate about delivering the training because I now know more about the whole process.”

Kristy Sheteron, Continuous Improvement Engineer St. Jude Medical

12 TBM LeanSigma Institute

KITBP

Kaizen Instructor Training - Business Process Seminar

www.tbmcg.com/kitbp | 800.438.5535

Kaizen Instructor Training - Manufacturing Operations Comprehensive Train the Trainer Program Critical kaizen instructor training that sets the foundation for dramatic improvement and successful culture change at the start of each shop floor kaizen event. Learn to conduct day-one training of lean concepts to build team awareness and support at the beginning of each kaizen event.

Ideal Attendees • Kaizen promotion office managers • Continuous improvement managers • Engineers

Key Learning • Lean and kaizen training content required to build team awareness and support at the start of each kaizen event • Advanced instructor presentation, training and teaching skills – for maximum impact • Preparation techniques for kaizen events to ensure peak results • In-depth familiarity with all training materials • Interactive simulation exercises and anecdotes to reinforce key concepts • Responses and role plays for questions your instructors will commonly receive

Tools Learned • “Train the trainer” techniques

Pricing • Individual: $3,250 • Group: $2,750 each, for three or more people from the same company

Prerequisites Attendees without a signed material licensing agreement will be charged an additional $500 for access to licensed training materials. The minimum experience level required is four manufacturing kaizen events. In order to maintain a consistent level of experience among course attendees, we will conduct a brief interview to determine your level of lean experience before admittance is approved.

Four-Day Agenda Day One • • • •

Introductions and review LeanSigma overview How to be a trainer Five minute introduction presentations

Day Two • • • • •

Lean production system review Simulation 1: flow production Standard operations review Exercise 1: time observation Round one presentations

Day Three • • • • •

5S workplace organization Assembly review Setup reduction review Round two presentations Exercise 2: standard operations

Day Four • • • • •

Presentations video taping Total productive maintenance review Routing standardization review Kaizen breakthrough methodology review Key learnings

“A very enjoyable and informative week! I feel more passionate about delivering the training because I now know more about the whole process.”

Kristy Sheteron, Continuous Improvement Engineer St. Jude Medical

13 TBM LeanSigma Institute

KITMO

Kaizen Instructor Training - Manufacturing Operations Seminar

www.tbmcg.com/kitmo | 800.438.5535

Lean Management Accounting Simple Financial Reporting to Understand Your Lean Transformation A two-day workshop for finance teams and senior management on the critical need to align accounting practices with your Lean journey – and restore clarity to financial reporting.

Ideal Attendees • CFOs, Controllers, Plant Accountants, and Corporate Accountants • Lean Leaders • COOs, General Managers, and Plant Managers **Your experience will be most effective if your company sends a team including a mix of the above**

Key Learning At the completion of the course the participant will be able to: • • • • • • • •

Describe the key elements of lean accounting Understand the changed role of accounting in a lean organization Describe the risks of standard cost systems to a lean transformation Describe lean financial statements that do not violate GAAP Understand the principles of a Lean Measurement System Define steps to launch a lean accounting initiative Recommend initial processes to launch kaizen for accounting operations Simulation highlighting the impact of one piece flow on financial statements

Two-Day Agenda Day One • • • • • •

Introductions and expectations General lean overview Simulation Obstacles for lean accounting Cost management Costing and absorption accounting

Day Two • • • •

Accounting processes Performance measures Investment management Roadmap to get started

The Long-Term Payoff • Financial statements in plain English – available at the end of the month, not weeks later • Clear, accurate pictures of lean improvement and overall business performance • Information that can be easily understood and acted on by business managers with no accounting background • Faster, simpler and more customer-focused accounting processes • Finance teams that efficiently support the growing lean business as full partners in lean change

“This is the best workshop I have attended in my 12 years as an accounting professional.”

Scott Juengel, Plant Controller Michelin Tire Corporation

Pricing • Individual: $1,500 • Group: $1,350 each, for three or more people from the same company We can conduct this workshop onsite at your facility for groups of 10 or more.

Prerequisite Participants will have good knowledge of lean manufacturing, but may have had little or no exposure to lean accounting.

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LMA

Lean Management Accounting Seminar

www.tbmcg.com/lma | 800.438.5535

LeanSigma for Process Industries Lean Immersion Workshop for Continuous Process Companies A senior-level overview for continuous process companies of a proven business strategy for rapidly achieving dramatic performance improvement with LeanSigma – in a fraction of the time of traditional Six Sigma.

Ideal Attendees • Senior management including: Chief Executive Officers, Presidents, Chief Financial Officers, and Chief Operating Officers • Operations management including: General Managers, Vice Presidents or Directors of Operations, Engineering, Continuous Improvement, Quality, Materials, Supply Chain, and Human Resources

Key Learning • Your company’s improvement potential – and a proven business strategy to quickly drive substantial improvement and efficiency across your entire value stream

Two-Day Agenda Day One • • • • • •

• How to seamlessly integrate lean and Six Sigma into a cohesive, enterprise-wide improvement initiative • How you can rapidly improve process yield with Sigma Kaizen events • How you can dramatically improve process capability and equipment effectiveness without significant capital investment • How you can rapidly reduce changeover and clean-out times by 75-90% • How you can achieve major productivity improvement by increasing throughput • How you can improve process flexibility to deliver to actual customer demand

Pricing

Introductions LeanSigma overview Simulation 1 Lunch Creating flexibility Initial implementation steps – Vision – 5S – Overall equipment effectiveness (OEE) – Process capability – Kaizen

Day Two • • • • • •

Final implementation steps Simulation 2 Business process kaizen Product development Culture change Continuous improvement office

• Individual: $1,500 • Group: $1,350 each, for three or more people from the same company

“We’ve been using lean to achieve major, ongoing improvement. I knew it wasn’t the answer to some of our process variation problems, but how could I promote lean speed and action together with slow and methodical Six Sigma? TBM has figured out how to successfully combine the two, with lean speed and maximum impact. This workshop put it all together for me – it was the same type of ‘ah ha’ experience I had when first introduced to lean.”

Rob Tracy, Chief Operating Officer Intek Plastics, Inc.

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LSPI

LeanSigma for Process Industries Seminar

www.tbmcg.com/lspi | 800.438.5535

Lean Tool Kit Workshop Continuous Improvement Essentials A five-day workshop covering lean tools and how they can be integrated as business strategies to achieve improved operational results.

Ideal Attendees • • • • • •

Executives Managers Supervisors Continuous improvement leaders Engineers Shop floor personnel

Key Learning • Participants are provided an overview of the lean roadmap and the Kaizen Breakthrough Methodology • How policy deployment drives the lean implementation process • Lean Tools covered include: value chain mapping, waste identification, takt time and process balancing, pull systems and kanban, jidoka, set-up reduction, total productive maintenance, quality, Sigma Kaizen, and 5S • Extending lean into the value chain • Factory simulations and workshop exercises

Tools Learned • • • • • •

Value chain mapping Waste elimination Progressive 5S Setup reduction Total productive maintenance Kanban

Pricing • Individual: $3,450 • Group: $2,950 each, for three or more people from the same company

Five-Day Agenda Day One • Lean overview • Importance of KPI’s and countermeasure system • How policy deployment aligns vision, strategy, and resources Day Two • Factory simulation 1 • Value chain mapping • Waste elimination Day Three • • • • • • • •

Lean production system Progressive 5S Standard operations Time observation example Setup reduction Total productive maintenance Quality and Six Sigma Kanban

Day Four • • • •

Factory simulation 2 Design for LeanSigma Energy kaizen Lean Value Chain

Day Five • Business process kaizen • Kaizen breakthrough methodology • Review of the week

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LTK

Lean Tool Kit Seminar

www.tbmcg.com/ltk | 800.438.5535

Leveraging LeanSigma® for Growth The Executive’s Guide for Enterprise-Wide Business Transformation An interactive two-day workshop for senior manufacturing executives who wish to create a clear, concise and compelling vision, and leadership roadmap for business transformation.

This workshop focuses on using the powerful and proven tools of LeanSigma, the Kaizen Breakthrough methodology, and Value Innovation to create unique competitive advantages and a high-performance culture for exceptional growth in sales and earnings.

Ideal Attendees • Senior business leaders including: Chief Executive Officers, Chief Financial Officers, Chief Operating Officers, and division heads responsible for delivering shareholder returns and creating sustainable stake holder values.

Background CEO Anand Sharma and senior leaders of TBM have been helping companies throughout the world with physical and cultural transformations that drive company growth and improve financial performance using the same principles of continuous improvement tools that transformed Toyota into the world class company that prospered in good times and bad. While many manufacturing and service companies will say they have a continuous improvement initiative in place, very few have evolved lean, six sigma or any combination of tools into a consistent business philosophy with a clear vision, set of values, objectives, and sustainable processes that result in superior performance and exceptional shareholder returns.

If you intend to drive above-average growth in sales and profitability with minimum resources you must develop a cohesive, strategic direction, sustainable competitive advantages, innovative products and capable leaders who execute strategy with a consistent process across the board. Consider this two-day “working meeting” as a springboard for your journey into a new business system that paves the way for unparalleled customer satisfaction and a relentless focus on continuous improvement.

Key Learning • Overview of a lean business system evolution, its history, success stories, mission, and infrastructure for success.

• Key principles, methodologies and drivers of a three-to-five year LeanSigma business transformation journey for growth with numerous case studies, simulations and interactive, provocative discussion.

• A process for creating a compelling vision for change guided by a proven methodology for strategy deployment, metrics alignment, visibility and accountability.

• Insights into the role of senior management in leading a successful transformation and a roadmap for physical and cultural transformation that engages hearts and minds.

Two-Day Agenda Day One • Introductions & expectations • Lean business system overview with proven case studies • First manufacturing simulation • How to build a foundation for long-term success • Creating a compelling vision • Leadership roles & responsibilities • Strategy / Policy Deployment • High performance culture

Day Two • Fundamental LeanSigma tools • Methodology and process for driving rapid change • Lean production system overview • Second manufacturing simulation • Extending continuous process beyond manufacturing • How to leverage LeanSigma as a strategy for long-term growth and sustainable profitability • Creating a customer-facing approach to value innovation and rapid product development • How to get started TBM has worked with hundreds of companies over the past twenty years.

These are a few examples of companies using a LeanSigma Business System to run a different, winning race.

Pricing • Individual: $1,500 • Group: $1,350 each, for three or more people from the same company Companies like Toyota and Danaher are commonly mentioned as representative examples of successful lean business systems.

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LLG

Leveraging LeanSigma for Growth Seminar

www.tbmcg.com/llg | 800.438.5535

Managing for Daily Improvement Training Learn How to Sustain Improvements Resulting from Your Lean Operations A five-day workshop, taught on the shop floor of a leading lean company, that will provide you with the opportunity to learn the tools and techniques you need to implement and sustain daily continuous improvement initiatives in your work area.

Ideal Attendees • • • •

Front-line supervisors, team leaders, and line facilitators Production, process, and support group managers and their key staff members Continuous improvement or kaizen promotion managers Plant, division, and department managers

Key Learning • • • • •

Critical supervisor training Leverage lean tools to identify problems and highlight resources needed Respond immediately to abnormalities Learn to apply point kaizen strategies Create critical performance metrics

Tools Learned • • • • • • • •

Progressive 5S Visual workplace techniques SQDC boards Waste elimination Standard operations Point kaizen Abnormality management Kaizen planning

Five-Day Agenda Monday • Introductions and overview • Lean progression and barriers to success • Delta site review Tuesday • Visual workplace • SQDC management Wednesday • Waste elimination • Standard operations • Point kaizen Thursday • Solving quality problems • Abnormality management • Kaizen planning model Friday • Final review • Presentation preparation • Presentation to management

Pricing • Individual: $3,450 • Group: $2,950 each, for three or more people from the same company

“Managing for Daily Improvement is one of the most important aspects of a LeanSigma® transformation.”

Mike Hofmann , Executive Vice President of Operations for North America Sealy, Inc.

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MDI

Managing for Daily Improvement Training Seminar

www.tbmcg.com/mdi | 800.438.5535

Quest for the Perfect Engine Learn What it Takes to Launch Lean in Your Company A top-level overview using discussion and interactive simulations that demonstrate how the LeanSigma® methodology provides a platform for effective change. Discover what’s required to lead your own transformation for gaining and sustaining market leadership.

Ideal Attendees • Senior management including: Chief Executive Officers/Presidents, Chief Financial Officers, and Chief Operating Officers • Operations management including: General Managers, Vice Presidents or Directors of Operations, Engineering, Continuous Improvement, Quality, Materials, Supply Chain, and Human Resources

Key Learning • How to start a lean initiative and sustain momentum • How the powerful combination of lean and Six Sigma can be used to remove guesswork • How lean methods quickly eliminate non-value-added activities and processes • Understand your company’s improvement potential – and how you stack up versus your industry and the ideal lean company • How to rally the organization around improvement objectives • How to sequence for your improvement activities • How to leverage lean as a strategy for innovation, differentiation, and growth

Pricing • Individual: $1,500 • Group: $1,350 each, for three or more people from the same company We can also conduct this workshop at your site for groups up to 24.

Two-Day Agenda Day One • • • • •

Introductions and expectations Discussion: The “ideal” manufacturer Analysis: Where you are vs. the ideal Simulation 1: traditional manufacturing Discussion – Components of traditional manufacturing – Principles of LeanSigma/ kaizen breakthrough • Simulation 2: application of LeanSigma principles Day Two • Discussion – Integration of lean and Six Sigma practices – How, when, and where to apply LeanSigma for maximum improvement – Extension of LeanSigma across value chain (suppliers and customers) – Information management requirements • Simulation 3: value chain application and synchronization • Discussion – Why new product development must be included in the process – How to create and perpetuate a culture of continuous improvement

“Quest for the Perfect Engine is like a two-day lesson from the game’s top pro.

A not-to-be-missed learning experience. Definitely a ‘10’ on my scale.”

Thanasis Molokotos, President and CEO ASSA ABLOY Americas

19 TBM LeanSigma Institute

QPE

Quest for the Perfect Engine Seminar

www.tbmcg.com/qpe | 800.438.5535

Quest for the Perfect Engine® Leveraging Lean for Competitive Advantage in the Garment Industry A two-day workshop using discussion and interactive simulations that demonstrate how the LeanSigma methodology provides a platform for effective change.

Tailored specifically for senior-level managers in the garment industry looking to understand what it takes to drive a lean transformation.

Ideal Attendees • Senior management including: Chief Executive Officers, Presidents, Chief Financial Officers, and Chief Operating Officers • Operations management including: General Managers and Vice Presidents or Directors of Operations, Engineering, Continuous Improvement, Quality, Materials, Supply Chain, and Human Resources

Key Learning • How to start a lean initiative and sustain momentum • How the powerful combination of lean and Six Sigma can be used to remove guesswork • How lean methods quickly eliminate non-value-added activities and processes • Understand your company’s improvement potential – and how you stack up versus your industry and the ideal lean company • How to rally the organization around improvement objectives • How to sequence for your improvement activities • How to leverage lean as a strategy for innovation, differentiation, and growth

Pricing • Individual: $1,500 • Group: $1,350 each, for three or more people from the same company

Two-Day Agenda Day One • • • •

Introduction of lean transformation Case studies of successful lean companies Simulation 1: traditional manufacturing Introduction to lean concept: – Value chain mapping – The seven wastes – Valued-added versus non-valueadded activities – 5S – Lean production system • Simulation 2: one-piece flow, pull production, integrating lean, and Six Sigma Day Two • Lean production system – Change over reduction methods – Production smoothing and mixed-model production – Material management by using pull, LeanSigma value chain • Simulation 3: pull system, mixed models • Developing a culture to sustain your gains • Business process kaizen • LeanSigma product development • Review of expectations • Getting started and recommendations for next steps

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QPEG

Quest for the Perfect Engine - Garment Industry Seminar

www.tbmcg.com/qpeg | 800.438.5535

Sustaining Lean Results Audit, Report and Sustain Kaizen Results A five-day workshop that gives you strategies, tools, and skills required to preserve the returns of your continuous improvement program.

Ideal Attendees • • • •

Operations management General managers Plant managers Lean or kaizen promotion office managers, continuous improvement leaders, and team members

Key Learning • Learn how to use performance measures, targets, and tracking strategies, including how to manage and sustain SQDC boards and hour by hour charts • Learn how to audit and report the results of each kaizen project to help sustain those results • Tools and techniques for creating a business control center to keep your lean transformation organized and on track • Understand how to use Layered Audits, an organized group of questions designed to examine a device or process, to ensure that standard work is being followed at all levels of the organization • Learn how to use the A3 Methodology to create information flow of knowledge, ideas and experience, which will help you to eliminate waste and solve problems through a visual, easily understood process • Understand and learn how to solve problems using the 8D methodology; You’ll learn several tools to identify the root cause and implement countermeasures using Poka-Yoke • Cultural transformation tools to help establish credibility for your improvement initiative, instill enthusiasm at all levels of your organization, and provide essential continuity and staying power • Personalysis training will help you understand your personality style and the team’s in order to take advantage of opportunities, rather than being blocked by interpersonal conflict

Five-Day Agenda Day One • Cultural transformation tools Day Two • Driving cultural transformation • Personalysis Day Three • Establishing performance measures • How to sustain results • Auditing and reporting kaizen results Day Four • • • •

Creating a business control center Conducting layered audits Understanding the A3 methodology Problem-solving tools and methodologies

Day Five • Problem-solving tools and methodologies

Pricing • Individual: $3,450 • Group: $2,950 each, for three or more people from the same company

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SLR

Sustaining Lean Results Seminar

www.tbmcg.com/slr | 800.438.5535

LeanSigma Global Summit Excellence Doesn’t Just Happen. It Has to be Achieved.

The LeanSigma Global Summit offers valuable content for organizations looking to build the foundational framework of a lean operating system that delivers value creation for shareholders and stakeholders alike.

Ideal Attendees

Two-Day Agenda

Senior leaders, functional leaders, operations management and continuous improvement teams from manufacturing, health care, financial services, and public sector organizations

Day One • Full day includes general sessions, four breakout sessions, and networking reception

Sessions For All Levels Breakout tracks focusing on increasing profitability and cash flow, driving culture change, improving speed to market, and growing market share

Day Two • Full day includes general sessions and four break-out sessions

Highlights • Align: Understand how the most successful LeanSigma deployments are aligned to deliver growth and meaningful, measurable results. You’ll leave the summit better equipped to effectively measure, lead and manage in a continuous improvement environment.

• Accelerate: Bring your entire continuous improvement team, your functional leaders—your suppliers or customers. Learn from seasoned lean leaders how they drive culture change, leverage tools, and manage performance metrics using the speed of lean and the precision of Six Sigma.

• Achieve: Build your professional network. Expand your library of best practices. Expose your team to new tools and techniques. Learn how you can do more, achieve more, and win through the effective integration of operational excellence.

Pricing • Individual: $2,500 • Groups of 3-9: $2,250 • Groups of 10+: $1,750

The agenda for this event is updated frequently. Please go to www.tbmcg.com/lsgs for more information on the conference program.

The LeanSigma Global Summit is hosted in the United States.

“A great way to get refocused and rejuvenated – and share new experiences and discoveries.”

Daren Meints, Area Manager Pella Corporation

22 TBM LeanSigma Institute

LSGS

LeanSigma Global Summit Conferences

www.tbmcg.com/lsgs | 800.438.5535

Lean Excellence Conference Networking, Benchmarking and Strategies for Your Continuous Improvement Office The Lean Excellence Conference is an outstanding forum to benchmark and network with other continuous improvement managers in the lean community. Choose from a contentrich program of breakout sessions and panel discussions tailored for lean managers.

Ideal Attendees Managers and leaders responsible for continuous improvement implementation inside their organizations. Attendees should be familiar with lean and looking to learn the latest continuous improvement tools and techniques

Highlights At the Lean Excellence Conference you’ll have the opportunity to benchmark best-in-class lean practices and participate in breakout sessions on today’s highest priority topics. There will be an expanded agenda with unique discussion tracks on topics that include:

Two-Day Agenda Day One • Full day includes general session, breakout sessions, and plant tour.

Day Two • Full day includes general session, breakout sessions, and a roundtable discussion.

• Policy Deployment • Lean and Culture Change • Business Process Improvement • Managing for Daily Improvement

Pricing • Individual: $975 • Group: $815 each, for three or more people from the same company The Lean Excellence Conference is hosted in the United Kingdom.

The agenda for this event is updated frequently. Please go to www.tbmcg.co.uk/lec for more information on the conference program.

“As usual, very well done! I have found this conference to be time well spent.

The opportunity to network with peers and have open, honest conversation with them is invaluable to me in moving us forward in our lean journey.”

Henry Nolan, Kaizen Promotion Office Coordinator Wise Business Forms

23 TBM LeanSigma Institute

LEC

Lean Excellence Conference Conferences

www.tbmcg.com/lec | 800.438.5535

TBM Essential Lean Learning Lean Learning at Internet Speed A comprehensive, self-paced interactive online training program designed to provide rapid knowledge transfer of essential lean learning.

Speed up your organization’s lean transformation by training your organization on basic lean concepts and applications with Essential Lean Learning, available at the new TBM Online Learning Center from the TBM LeanSigma® Institute.

Ideal Attendees • • • •

Shop floor associates, team leaders, and supervisors Leadership & management teams Suppliers & customers Participants in continuous improvement in the areas of: – Production – Engineering – Quality – Materials Management – Distribution – Business Process – Sales, Marketing, and other Administrative Functions

Key Learning • Designed by TBM lean practitioners and based upon our experience developing and teaching LeanSigma® methodologies and grounded in our roots of the Toyota Production System • The first comprehensive online training program for lean • Affordable, easy to implement, and track. At any time, we can easily let you know who completed the training and how they performed • Self-paced, web-based, easily deployed from any web browser • Complex topics made simple – interactive exercises with simulations that reinforce key learning • Get everyone speaking a common language about lean by training an infinite number of employees in a short period of time

Pricing

Essential Lean Learning (A 12-Module Curriculum)

LeanSigma Overview

Progressive 5S & the Visual Workplace

Individual Learner

$289

$79

$79

2-25

$249

$69

$69

26-100

$209

$59

$59

101-500

$179

$49

$49

501+

$139

$39

$39 Your Role in the Company’s Transformation

See How the Examples and Exercises Make Complex Topics Simple and Memorable.

Try the demo as many times as you like. Share it with other decision makers in your organization. Then give us a call and let us know how we can help you meet the challenge of training an infinite number of employees at Internet speed.

Go to www.tbmcg.com/learnonline and take the demo today.

24 TBM LeanSigma Institute

ELL

TBM Essential Lean Learning Online Learning

www.tbmcg.com/ell | 800.438.5535

TBM Essential Lean Learning Lean Learning at Internet Speed

12 Modules Of Essential Lean Learning Introduction to the LeanSigma Journey

100

Understand what’s required to begin your lean transformation. Become familiar with the major objectives of lean and fully understand why you are embarking on a lean journey.

LeanSigma Overview & the Time-Based Strategy

101

Understand how LeanSigma is a business strategy for growth and profitability— and how lead-time reduction will improve quality, cost, and deliver performance.

The Seven Wastes

102

Production Smoothing

105

Define production smoothing and describe how it is used to meet rates of variation in customer demand. Calculate optimal product mix by using takt time along with a product mix table.

Standard Operation Tools

Define cycle time. Explain why time observation is an effective method of analyzing a process to identify waste.

Become familiar with tools to evaluate operator work balance within a group.

Define standard work in process as the minimum amount of material required to complete the work sequence on demand.

LeanSigma Implementation

110

Define the kaizen breakthrough methodology as the rapid improvement of a process through the use of a crossfunctional team. Grasp key kaizen principles and understand how to define key objectives for each of the five days of a kaizen event.

103

Understand the concepts of takt, flow, and pull. Learn to calculate takt time as the pace for customer demand. Differentiate between push and pull production systems.

Continuous Improvement through Standard Operations

107

Understand the role and importance of standard operations. Describe how standard work in process enables the completion of the work sequence to demand.

Quality & Productivity Improvements through Jidoka

109

Define the steps for creating a value chain map to use as the visual tool for displaying the flow of information and material through a process.

106

Differentiate between value-added and non value-added activities. Understand the three criteria to qualify as value-added activity. Identify and understand the seven categories of waste.

Just-in-Time Principles: Takt, Flow and Pull

Value Chain Mapping

Progressive 5S & the Visual Workplace

104

Understand the importance of identifying the problem and establishing a process to fix issues as they occur. Recognize the role of Jidoka to improve quality and productivity.

108

Define and demonstrate 5S as a process and method for creating and maintaining a safe, organized, clean, and highperformance workplace. Define the 5Ss in progressive 5S and state the key activity of each “S”. Explain how to use the score sheet as a tool to improve 5S.

Your Role in the Company’s Transformation

111

Understand how to make a significant difference in a company’s objectives to drive growth, earnings, and its reputation as a challenging and rewarding place to work and grow.

25 TBM LeanSigma Institute

ELL

TBM Essential Lean Learning Online Learning

www.tbmcg.com/ell | 800.438.5535

Our Team Each LeanSigma Institute instructor is a senior TBM consultant who’s spent more than ten years, hands-on, actually implementing the lean principles he’s teaching. They spend most of the year in the field, leading client teams to rapid, dramatic performance improvement, which enables them to bring a wealth of real-world experience to every workshop.

John Alford Senior Management Consultant John is a Senior Management Consultant for TBM Consulting Group with extensive experience directing lean programs in the automotive industry. Before joining TBM, John spent 32 years at Ford Motor Company working in a number of manufacturing roles including: assembler, supervisor, and maintenance leader.

His strengths lie in teaching and coaching with specialized expertise in TPM, 5S, standard work for managers and operators, supervisor development, set-up reduction, and material development. John teaches lean training courses and certification for the LeanSigma Institute and consults with numerous clients in industrial products, consumer products, and garment manufacturing including Gokaldas Imports, Youngone, and Owens Corning.

Bob Dean Executive Vice President – Dploy and Technology Bob has been implementing lean with companies from the manufacturing and service sectors worldwide for over 20 years. He maintains close ties with the Japanese team responsible for the Toyota Production System and was instrumental in creating TBM’s proprietary LeanSigma process, the seamless integration of today’s most powerful business improvement tools. He teaches Creating a Continuous Improvement Office, Lean Management Accounting, and LeanSigma for Process Industries.

Martial Durin Vice President – TBM China and Asia Pacific A manufacturing engineering leader with nearly 20 years lean experience, Martial brings a global background to TBM clients. Trained in the Toyota Production System in Japan, Martial has helped companies from Europe and China to Africa and the Middle East transform using lean principles. Martial is especially valued for his teaching and team-building skills and for his extensive background in manufacturing and business process improvements. He teaches Quest for the Perfect Engine.

Richard Holland Vice President – Central Hub Consulting A lean practitioner since 1995 and a Six Sigma Black Belt, Richard comes to TBM with more than 10 years in discrete manufacturing in the automotive, aerospace, and consumer goods industries. He brings expertise in supply chain management— in both inbound and outbound distribution channels—as well as freight management, machining, and assembly. He teaches Creating a Continuous Improvement Office, Kaizen Breakthrough Experience, LeanSigma for Process Industries, Quest for the Perfect Engine, and Kaizen Instructor Training.

Gary Hoover Vice President – Central Hub Business Development A former leader in both manufacturing and sales, Gary has enjoyed broad experience, from policy setting in Washington, D.C. to supervising high-tech manufacturing. Gary has proven strength in working through complex value chain issues, pinpointing defects that effect equipment utilization, and strategizing transformation goals. He teaches Quest for the Perfect Engine.

26 TBM LeanSigma Institute

www.tbmcg.com | 800.438.5535

Our Team (con’t) Michael Latuga Vice President – TBM Mexico Michael was a former plant manager with international experience, and has more than 2 decades of experience in business and manufacturing. He developed an expertise in turning around troubled plants throughout the world during his 22-year career with United Technologies/Carrier. He also has broad experience in supply chain management, operations, strategy, and implementing continuous improvement. He teaches LeanSigma for Process Industries and Quest for the Perfect Engine.

Tom Morin Director – Client Manager Tom has more than 20 years of global experience leading business wide LeanSigma® implementations and cultural transformation in manufacturing and service industries. He is particularly recognized for his broad experience in business process kaizen and lean implementation as well as his technical expertise in set-up reduction, machining and fabrication. Tom has been a trusted advisor for clients such Reviva, EA Sween, Carlisle, State of Iowa, First Data, Lantech, Hillenbrand, and Hayward Pool Products and is often called upon to teach courses for the TBM Institute. He now leads TBM’s business development efforts by working with prospective clients and helping them define the scope of training, technology, and consulting services they require for achieving effective business results.

Joe Panebianco Director – Customized Training Leader A former operations manager with broad manufacturing and business experience, Joe came to TBM in 2003 after more than a decade in the industry. At TBM, Joe is sought after for his team-building and leadership skills, as well as his ability to help clients visualize and develop a transformation plan. He is uniquely skilled in effectively interfacing with all levels of an organization to facilitate change. He teaches Kaizen Breakthrough Experience, Lean Certification, Lean Management Accounting, LeanSigma Vision Tour, and Kaizen Instructor Training.

Gary Rascoe Senior Trainer and Design Specialist A LeanSigma black belt with extensive experience in both operations and business processes, Gary came to TBM in 1995. He is especially sought after for his expertise in integrating business processes with lean operations and has led successful kaizen events and company-wide lean implementations for more than a decade. He teaches Lean Certification, Lean Management Accounting, LeanSigma Vision Tour, Lean Tool Kit, Creating a Continuous Improvement Office, Kaizen Instructor Training, and Sustaining Lean Results.

Anand Sharma President & CEO Anand is widely considered a leading global authority on business improvement. Named a “Hero of US Manufacturing” by Fortune, recipient of the Burnham Manufacturing Management Award by the SME, and member of the Shingo Prize Academy, he is also a columnist for The Manufacturer and frequent speaker at gatherings such as the AME Annual Conference and Manufacturer Live UK. Anand has been leading lean transformations for over 20 years, with expertise learned firsthand from the developers of the Toyota Production System. He teaches CEO Boot Camp and Quest for the Perfect Engine.

27 TBM LeanSigma Institute

www.tbmcg.com | 800.438.5535

Important Information Schedule The LeanSigma Institute global course schedule is updated frequently, so for the most current version, please visit our website: www.tbmcg.com/schedule. The schedule is segmented by course name, date, and region.

Terms and Conditions You will be invoiced for event fees which are due in full prior to the start of each workshop. Event fees include workshop materials, lunch, and refreshments. Please see event descriptions for any prerequisite requirements prior to registration.

Transfers and Substitutions Substitutions are allowed at any time. Transfers to another date will only be accommodated one time.

TBM is committed to fulfilling the schedule as presented, however TBM reserves the right to cancel any courses where sufficient registration levels have not been met.

Cancellation Policy Any cancellation must be received in writing. Cancellations received within 15-21 business days of the event will be subject to a 50% cancellation fee. Cancellations received within 0-14 business days of the event will be subject to a 100% cancellation fee.

Unconditional Guarantee If, for any reason, you are not satisfied with this workshop, we will refund 100% of your fee.

“How many consulting firms unconditionally guarantee every aspect of their work? TBM is the only one I know of.”

Tim Powers, Chairman & CEO Hubbell Incorporated

28 TBM LeanSigma Institute

www.tbmcg.com | 800.438.5535

About The LeanSigma® Institute Certification • Seminars • Conferences • Online Learning • Events • Customized Training The LeanSigma Institute is the training arm of TBM Consulting Group, the leader in operations management and business process improvement. We help you to develop the internal talent and lean culture you need to independently accelerate and sustain performance resulting from your lean transformation.

Our clients come from a broad array of manufacturing industries including industrial components and assembly, automotive, aerospace, packaging, heavy equipment, food and beverage, medical devices, pharmaceuticals, railways, consumer products, durable goods, retail, distribution, building products, and more.

We offer a wide variety of lean training and development activities for all roles of the organization regardless of your lean maturity level. The more we understand your specific business challenges, the better we can suggest, develop or deliver a training program that meets the needs of leadership, management, supervisors, and associates throughout the organization—in both manufacturing and supporting office functions.

We offer the following comprehensive suite of training solutions: • A complete curriculum of lean workshops delivered at your facility or in the classroom, on the shop floor or in administrative functional areas such as product development, accounting, sales and marketing or customer service • Train-the-trainer, mentoring, and certification programs • Tailored lean training program development and delivery • Cultural assessment and leadership development • Content development and material licensing • Online training / Lean eLearning

What’s different about the LeanSigma Institute?

• • • • • • •

Alignment of training delivery with business results All trainers experienced with hands-on lean implementations Ability to deliver content and training in multiple languages Local resources in North America, Europe, South America, India, and Asia Proven approach to lean transformation and culture change Work with you to create a flexible approach and content for your lean training program Robust library of training materials, instructor notes, simulations, videos, and facilitator guides

We can help you create the right training program for lean practitioners, mid-level managers, or executives including awareness training, leadership and culture training, skill development, or certification.

29 TBM LeanSigma Institute

www.tbmcg.com | 800.438.5535

Worldwide Offices TBM Consulting Group, Inc. and LeanSigma Institute

TBM USA Corporate Headquarters 800.438.5535 TBM Brazil 55.11.5051.7490 TBM China 86.21.6888.6671

TBM France 33.472.91.32.88

TBM Mexico 52.81.50.00.91.36

TBM Germany 49 (0) 6221.825.835

TBM Switzerland 41.22.710.77.70

TBM India 91.124.437.5995

TBM United Kingdom 44.1623.758.298

LeanSigma速, TBM and the TBM logo are registered trademarks of TBM Consulting Group, Inc.

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