UP Consulting uses an action learning methodology that combines
workshops with hands-on consulting. This enables rapid and effective
transfer of skills, while simultaneously and measurably improving
operations. We believe the successful deployment of the Lean Enterprise
requires a comprehensive approach, giving equal attention to traditional
lean tools and techniques as well as Business Infrastructure and
Social Lean (changes in philosophy, culture and decision making).
Lean Overview
“Lean” is a powerful business methodology that helps
people at every level of an organization identify and eliminate
waste. This workshop introduces the principles of Lean and discusses
practical ways of applying proven tools that are helping businesses
world wide improve performance. Through the use of hands on
simulations participants will experience using Lean methods
and tools to create more effective business processes.
- Introduction to Lean
- Explore the elements and tools of a Lean enterprise system
- Describe the organizational impact of a Lean transformation
- Learn how to use simulations to demonstrate Lean principles
- Define key Lean metrics and relate them to business performance
- Identify opportunities for applying Lean
1 day |
Value Stream Mapping
Creating value for customers and clients is what business is
all about. Value Stream Mapping is a highly effective and practical
tool that creates a visual representation of any kind of business
process. That visual “picture” is then used to effectively
target business process improvements. This highly interactive
workshop uses hands on techniques to help participants learn
how to “see” and physically map the flow of value
creation through a business.
- Define value and the value stream
- Introduce value stream mapping in a hands on approach
- Develop the ability to see the flow of customer value
- Learn how to identify improvement opportunities.
- Begin to explore future state value streams
1 day
Return to Top |
Standard Work & Cellular Design
Having a consistent, effective work process is one of the corner
stones of any successful business. Standard Work and Cellular
Design are structured approaches to developing and implementing,
consistent high quality work methods. Standard Work documents
the best practice for performing the tasks needed to complete
a job while Celluar design links those jobs together in an efficient
and repeatable flow. Together these tools form the basis for
process improvements and improved out put.
- Describe and demonstrate Lean tactics and process stability
tools
- Perform detailed operations analysis
- Standard Work Design
- Standard Operations and Work Combination Sheet
- Cellular Process design and Workstation Layout
- Ergonomic considerations
1 day |
5S and Visual Management
5S and Visual Management are improvement practices that are
used in the early stages of helping businesses improve their
quality and productivity. 5S which stands for Sort, Store, Shine,
Standardize and Sustain helps business develop cleaner, safer,
more efficient operations with clearly visible processes and
inventories. Visual Management uses visible signals and graphics
to help everyone involved in a process make better decisions
and work more effectively. Properly applied these methods can
have a significant positive impact on safety, morale, productivity
and quality in the workplace. This workshop will cover the basics
of 5S and Visual Management and show examples of how they are
applied in real world situations. The concepts of “Lean”
will also be explored and how 5S and Visual Management help
identify and eliminate waste in business practices.
- Introduction to the 5 S process
- 5 S Implementation
- Benefits of establishing the Visual Workplace
- Visual Control techniques
- Visual Communication
- Visual Management
- Lean concepts
1 day
Return to Top |
Setup Reduction and Total Productive
Maintenance
Any business process that goes from one output to another contains
change over or “set up” time. Customer responsiveness,
inventory and quality are all directly impacted by the length
and consistency of the change over process used. This workshop
will explore proven methods for reducing change over time and
implementation practices that help business realize the full
benefits. Many businesses have seen set up times reduced by
50% or more with little or no capital investment. This workshop
will also explore the basics of Total Productive Maintenance
(TPM) and how equipment and process effectiveness relate to
business performance.
- Structured method for reduction of changeover time
- Advantages and business benefits of quick changeover
- Change over time in office and business applications
- Implementation strategies
- Basics of Total Productive Maintenance
- Overall Equipment Effectiveness
- Measuring and using OEE
1 day |
Kanban and Strategic Inventory
A Kanban system is among the simplest, most effective, and least
expensive means for production and inventory control. The concept
is to use simple signals to maintain carefully selected amounts
of inventory at strategic locations to maximize business productivity.
These methods are proven to reduce inventory, eliminate stock
outs and improve both service and quality. This workshop will
cover the concepts, calculations and implementation process
in easy to understand, practical approach.
- Inventory basics
- Evolution of replenishment methods
- Types of Buffer Stock and their uses
- Kanban types
- Kanban Fundamentals
- Implementing Kanban
- Integrating Kanban with existing systems
1 day
Return to Top |
Mistake Proofing with Poka Yoke
Poka Yoke is a set of tools and techniques designed to "mistake-proof"
a process or product. This workshop introduces participants
to the concepts of mistake proofing in a fun, hands on way.
The use of Poka Yoke can result in substantial improvements
in quality and cycle time in almost any kind of business. The
idea is to eliminate mistakes in a process or product by designing
the detection and correction methods right into the systems
being used. This session will cover both office and production
systems, as well as the steps used to select and implement Poka
Yoke correctly.
- Theory and Principles
- Types of mistake proofing
- Selection and implementation
- Product Design Applications
- Manufacturing Process Applications
- Inspection Process Applications
- Business Process Applications
1 day |
Ergonomics and Work Station Design
This seminar will give participants a basic understanding of
the science of ergonomics and how it can be applied to cumulative
trauma disorders. Resulting in easier work methods reduced injuries
and improved productivity. Also covered will be the knowledge
to effectively identify ergonomic hazards, pulled muscles, fatigue,
back strains, stress etc. A review of simple techniques that
can be applied by every employee in the work force to avoid
these types of injuries, whether you are in an office or much
more physical environment are also covered. If you sit at a
computer all day, you might want to consider this program.
- Introduction and ergonomics defined
- Analyzing the workplace
- Identifying risk factors
- Ergonomics job hazard analysis
- Controlling risk factors
- Implementing controls
- Medical management
- Ergonomics education and training
1 day
Return to Top |
Continuous Improvement and Problem Solving
Creating and sustaining improvements in any business is hard
work. This seminar will cover the use of specific techniques
and methods for creating and sustaining, business process improvements.
These tools and techniques can be applied in manufacturing as
well as the office, retail, service, and non-profits, in short
anywhere people work to provide a service or product. Classes
are interactive with exercises for hands on development of skills.
- Techniques for visualizing processes
- Team managements tools
- 7 key problem solving tools
- Basic problem identification methods
- Root Cause Analysis
- Change management·
- Holding the gains
1 day |
Lean for Team Leaders
This three-day course offers an intensive learning approach
on how to employ Lean principles in creating a business transformation.
“Lean” is a powerful business methodology that helps
people at every level of an organization identify and eliminate
waste. This series of highly interactive workshops introduces
you to Lean and helps develop the technical, change agent and
leadership skills needed to successfully get teams to implement
Lean in a wide variety of business environments. The focus of
both the class time and the exercises is on practical implement
of proven techniques that are helping businesses world wide
improve performance.
Session One – Fundamentals of the Lean Enterprise
Session Two – Creating Action
Session Three – Sustaining Success
- Introduction to Lean
- Organizing for change
- Managing and accelerating change
- Project selection
- Team selection and team building
- Benefits capture
3 days over one month
Return to Top |
Lean Office (for Managers and Supervisors)
This seminar offers participants a basic understanding of what
Lean is and how to apply Lean principles and practices in an
office environment. “Lean” is a powerful business
methodology that helps people at every level of an organization
identify and eliminate waste. Practical methods for identifying
improvement opportunities in paper and data transactions, process
steps, floor space and communication will be covered. Simulations
and exercises are used are used to demonstrate the methods and
techniques covered in the session.
- Introduction to Lean Enterprise principles
- Strategic goals for improvement
- Improvement concepts & techniques
- Organizational impact of a Lean transformation
- Simulations to demonstrate Lean principles
- Key Lean metrics and relationship to business performance
- Identify opportunities for applying Lean
1 day |
Six Sigma Green Belt
Six Sigma is an approach to business that helped create nationally
recognized high performance organizations. This series of workshops
will provide participants with the basic tools and techniques
needed to begin helping businesses of every kind and size apply
this very powerful methodology. Based on identifying and eliminating
variation Six Sigma has been successfully applied in manufacturing,
product development, accounting and financial services, hospitality,
and non-profits. In effect anywhere there is a product or service
being delivered.Green Belts are Six Sigma practitioners, who
understand, and use, fundamental Six Sigma tools to identify
and eliminate variation and waste. This program is designed
to provide candidates with both a technical and practical foundation
for applying Six Sigma through classes, hands on exercises and
project work all within an interactive team environment.
- Introduction to Six Sigma
- Variation, what it is and it’s effect on business
- Structured approach to applying Six Sigma
- Working with the Six Sigma team
- Basic Data Collection and analysis
- Statistical foundations of Six Sigma
- Process Mapping techniques
- Problem solving and root cause identification
- Failure Modes and Effects Analysis
- Measurement Systems and business metrics
- Change management and organizational readiness
- Hands on simulations and exercises
- Applying Six Sigma to real world situations
- Participants Projects
4 days, over one month
Return to Top |
Lean Supply Chain Management
The need to remain competitive in a global economy has caused
many high performance companies to focus beyond their four walls,
and look for improvements in the supply chain. Learn Strategies
to optimize a lean supply chain.
- Understand the importance of a Supply Chain Strategy
- Identify key strengths and weaknesses in your supply
chain
- The pitfalls of ineffective supply chain management performance
- How to positively influence your supply chain
- Implementation
2 days |
Supply Chain Performance
Supply Chain Management is a strategy for significantly reducing
cost and time in the flow of goods, services, and information
from suppliers to customers. The objectives of Supply Chain
Management are Rapid Response, Value Generation, and Customer
Loyalty.
- Develop Commodity Sourcing strategies
- Principles of Lean thinking & how to apply to the
supply chain
- Apply total cost concepts in supplier selection
- The importance of Supplier Metrics & how to use them
3 days
Return to Top |
Six Sigma Overview (for Managers and
Supervisors)
This seminar is designed for those managers and supervisors
who are considering implementing Six Sigma and want to understand
its core concepts and benefits. Based on identifying and eliminating
variation Six Sigma has been successfully applied in manufacturing,
product development, accounting and financial services, hospitality,
and non-profits. In effect anywhere there is a product or service
being delivered. This session provides an overview of Six Sigma
methodologies, organizational requirements and implementation
strategies.
- Introduction to Six Sigma
- Understanding the Six Sigma breakthrough strategy
- Quick overview of statistical foundation and common tools
- Business and organizational benefits of Six Sigma
- Roles and responsibilities of the team members in Six
Sigma implementation
- Implementation approaches
1 day |
Quality Function Deployment with Hoshin
Planning
Quality Function Deployment (QFD) is a systematic approach to
identifying, documenting and communicating customer requirements
business wide. This workshop will cover the use of many tools
and techniques that have made this powerful methodology a strategic
corner stone for many world-class companies. Participants will
learn how to use graphic representations of product and process
requirements to identify, prioritize, and communicate customer
expectations. Implementation and business benefits as well as
communication strategies will be covered.
- Introduction to QFD
- The voice of the customer and the house of quality
- Planning the project – who to involve
- Product objectives – product “x”
- Prioritizing the objectives
- Implementing the use of QFD
1 day
Return to Top |
Design for Manufacture and Assembly
Made Easy
This seminar is intended to describe to participants the benefits
of incorporating DFM/DFA into design of a product or process.
The program will define DFM/DFA and identify reasons why a company
should apply its principles to the design process. A review
of identifying similarities and differences between conventional
and concurrent approaches to manufacturing and assembly as well
as reviewing the stages of DFM/DFA
- Introduction to Design for Manufacture and Assembly
- How to identify criteria for a good design
- Understanding basic DFM/DFA methods and principles
- Understanding DFM/DFA enablers
- Explanation of basic DFM/DFA methods and techniques
- Identify the benefits of DFM/DFA
1 day |
Cycle Counting to improve Inventory
Record Accuracy
Inventories represent a company’s largest financial asset.
Rigorous physical control and 98+% inventory records accuracy
are vital to the successful and profitable operation of an enterprise.
Each day, decisions involving large sums of money are based
upon on-hand and on-order inventory balances. If these balances
are wrong, the result will be excess inventory, part shortages,
missed schedules, high expediting costs, poor customer delivery
performance, and potential exposure to inventory write-offs.Effective
cycle counting provides the means to monitor the level of accuracy
and to identify and eliminate the source of record errors. Many
companies that have successfully implemented cycle counting
no longer perform costly and ineffective periodic full physical
inventories - a significant source of record errors.Ample opportunity
will be provided for participant questions and answers from
experienced instructors.
- The real purpose for cycle counting – root cause
analysis and mistake proofing
- The transaction data that impact inventory records and
values
- To control inventory related transactions to assure record
accuracy
- The essential elements and transaction edits for accurate
reporting
- The prerequisites for effective physical control of inventories
- Effective techniques for storing inventory
- Proven techniques to measure record accuracy
- Procedures for accurately performing cycle counts
- How to reconcile errors found during the cycle counting
process
- Processes for conducting effective periodic physical inventories
Return to Top |
