All Rights Reserved. Copyright © Bonfiglioli Consulting · 10 All Rights Reserved. Copyright © Bonfiglioli Consulting LEAN ADVANCED The content of the two full day training session

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All Rights Reserved. Copyright © Bonfiglioli Consulting

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The Lean Factory School® is a “touch and try” experience which enables participants to appreciate Lean Thinking approach in the field.

Just 20% of time is on theory and exercises follow immediately in order to encourage ideas sharing and to reinforce team working value.

A learning by doing experience

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Scope

Understanding the main Lean principles and techniques with a hands-on approach

Learning in a mocked-up factory

Testing continuous improvement by incremental outcomes

Experiencing the team-learning and team-building principles

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LEAN OFFICE

TRAINING SESSIONS: LEAN OFFICE and 5Ss in the OFFICE

ASSEMBLY LINE

TRAINING SESSIONS: LEAN BASIC, LEAN ADVANCED and VALUE STREAM MAPPING EXERCIZES

MACHINING

TRAINING SESSIONS: OEE & SHOPFLOOR MANAGEMENT, SMED APPROACH, 5Ss APPROACH, AUTONOMOUS MAINTENANCE.

ENGINEERING DEPT

TRAINING SESSIONS: MULTI-PROJECT MANAGEMENT, OVERCOSTS/OVERQUALITY COSTS AND FMEA APPROACH

MASTER LEAN SIX SIGMA: LEAN GREEN and LEAN BLACK BELT CERTIFICATIONS

Training packages

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Training Package detail

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LEAN OFFICE

The content of the one full day training session

Introductive session about training goals and Lean Offices approach

Offices routines simulations exercises. Teams are in charge to detect waste and then banish it

A briefing will follow each run to reinforce teams working spirit, to measure achieved performances by Lean metrics and to lunch

improvement plans to decrease/banish waste

Training about visible tools and techniques to map activities and processes

Lean Office

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5S COMPETITIVO


Introductive session about training goals and 5Ss approach to improve workstation performances

Implementation of the 5Ss approach (Sorting, Setting in Order, Shining, Standardizing, Sustaining) on office processes and following audit

to measure results after approach implementation

A briefing will follow each run to reinforce teams spirit, to measure achieved performances by Lean metrics

Training about visible 5Ss tools and techniques to implement Standardization phase

5Ss in the Office

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LEAN BASIC

The content of the two full day training session

Introductive session about training goals and product technical features

Electric engine assembling sessions implementing two techniques: isle and flow. Teams are encouraged to detect waste and then banish it

A briefing will follow each production run to reinforce teams working spirit, to measure achieved performances by Lean metrics and to

lunch improvement plans to decrease/banish waste

Focus training about Lean tools and techniques on assembly operations

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Lean Basic

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LEAN ADVANCED


Waste detection, and materials shortage, handling, inventory level, occupied space, motion mapping in the shoopfloor

KPIs definition to measure results in terms of productivity, occupied spaces, number of stoppages, etc

Lean Materials Management role model definition and following implementation (synchro and kits system; kanban and supermarket sizing

implementing a pull system)

Improvements measurement based on large scale optimization plans involving not only the whole organization but also key suppliers

Lean Materials Management role model definition and following implementation

Teams working spirit reinforcement

Lean Advanced

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Team working exercize to map value flow

Goals:

Providing a clear and comprehensive view of the flows in a products family

Highlighting the link between the materials and the information flows

Calculating the Flow Index

Waste Detection: Not Value Added Activities ( NVAA or “muda”).

Defining a Future State Map, decreasing existing waste

Implementing the Lean techniques (Kanban, 5S, JIT, TPM, SMED, etc.).

Value Stream Mapping

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MISURA OEE & SHOPFLOOR MANAGEMENT


Introductive session about training goals and TPM approach and OEE metrics

Launch of two separate runs to measure equipment losses and OEE

A briefing will follow each run to reinforce teams spirit, to deeply analyze OEE and TOP 5 losses

Training about Shopfloor Management tools and techniques to attach TOP 5 losses

OEE Metrics & Shopfloor Management

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METODO SMED


Introductive session about training goals and SMED approach to decrease and simplify set-ups times

Selection of the most representative change over (Change Over Matrix)

Launch of two separate runs to change set ups on a real equipment. Deviations will be detected and step by step eliminated

A briefing will follow each run to reinforce teams spirit, to measure achieved performances, to define new standards and to attack

deviations

Training about SMED tools and techniques strictly linked to equipment performances

SMED Approach

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5S COMPETITIVO


Introductive session about training goals, and 5Ss approach to improve workstation performances

Implementation of the 5Ss approach (Sorting, Setting in Order, Shining, Standardizing, Sustaining) in a real workstation

A briefing will follow each run to reinforce teams spirit, to measure achieved performances by Lean metrics

Training about visible 5Ss tools and techniques to implement Standardization phase

Training about how to conduct auditing in Sustain phase

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5S Approach

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The content of the one full-day training session on a real equipment

Training participants about equipment’s cleaning, lubrication, daily checking, eventual adjustment and how to detect anomalies in order to

improve performances and to increase life expectancy

Understanding Lean principles and techniques with a hands-on approach

Improving work environment in terms of equipment reliability in order to improve performances and quality products

Defining operating standards based on Visual Management techniques and ensuring their daily implementation by means of a check list

Autonomous Maintenance

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Multi-Project Management


By means of business games, participants will experience tools and techniques to:

Delivery-on-time

Meeting requirements

Interacting with other depts

Detecting and banishing waste

Detecting constraints and bottlenecks

Managing several projects at the same time

Designing and implementing Lean tools and techniques

Working in teams

Improving communication

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The meaning of Value: What features customers really value?

QFD (Quality Function Deployment) process implementation: a structured process to design product features starting from customer

needs/wishes and able to meet customers early expectations

DFMA (Design for Manufacturing&Assembling) approach implementation: technique to analysis products in order to decrease costs by

rationalizing components and assembly phase

VRP (Variety Reduction Program) approach implementation: a technique to review complexity in products families

Overcosts/Overquality costs approach implementation: a technique to detect costs and quality not appreciated by customers

Overcosts/Overquality Costs

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An approach toward the right questioning before replies represents real issues!

The one full day training session to learn how to analyze failure types and consequences and its quickly implementation

The FMEA is an approach to proactively detect real or potential breakdowns, issues or errors in a product or service. This training session

provides a hands-on approach by testing two real applications.

Implementation of DFMEA approach (Design Failure Mode and Effect Analysis) to analyze failure types in case these failures could be

overcome by improving project features

Implementation of PMEA approach (Process FMEA) to analyze the manufacturing process to detect and eliminate possible failure types

due to manufacturing phases

FMEA Approach

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Master Lean Six Sigma detail

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Master Lean Six Sigma

A highly customized training program for Lean Yellow, Green and Black Belts with an hands-on approach.

In details:

Online Assessment Test to define participants know how entry level and thus to customize following lessons

10 Front Lessons with a Master Lean Black Belt Trainer

2 days training session about Lean Thinking at our Lean Factory School®

Final Test and Project Work submission for each attendee to reinforce theory

Walking tours in Lean Six Sigma manufacturing plans to see achievable results first hands

Master Lean Six Sigma

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Some Clients we served

http://www.baltur.it/home.php

http://www.baltur.it/home.php

www.leanfactoryschool.it

Documents

All Rights Reserved. Copyright © Bonfiglioli Consulting · 10 All Rights Reserved. Copyright © Bonfiglioli Consulting LEAN ADVANCED The content of the two full day training session