Beyond 5S - Creating a Lean Culture Revoultion

Learn how to lock in the gains of 5S by developing work spaces that synchronise all aspects of daily work including:

• Receiving work instructions
• Time management/work tracking
• Materials, tools and spares management
• Research/information finding
• Dynamic workload balancing
• Administration/QA
• Control of compliance protocols

Understand how to engage those in the workplace with systematically improving Work Space Synchronicity to:

• Increase work plan adherence
• Adapt to variability in materials, people and order flow
• Efficiently incorporate agency/temporary personnel at times of peak loading
• Simplify control and compliance
• Reduce human error risks
• Release of management and support personnel from day to day activities to focus on higher added value tasks.

This 3 day workshop covers the theory and practice of work space design and the practical steps to deliver self-managed work processes. Processes that are easy to do right, difficult to do wrong and easy to learn. The outcomes includes:-

• Simplified, more resilient shop floor production, maintenance, planning, quality assurance and training processes.
• Transfer of management and support function standard work to front line teams
• Improve door to door quality cost and delivery performance
• A customised roadmap to guide the journey from passive to synchronised workspaces.

For managers, team leaders and change agents tasked with the reduction of shop floor waste and non-value added activities through the engagement of shop floor personnel with the improvement of:

• Work place systems and procedures including planning, booking in, kitting, material control;
• Workplace layout, organisation, flow and productivity;
• Rapid customer order fulfilment cycles;
• QA checks, in process testing/auditing;
• Training of personnel including temporary worker's/agency staff.

This will include the developing solutions around:

• The design and location of safety guards, enclosures, workstations, conveyors and transfer systems to simplify production processes, reduce waste and improve flow;
• The creation of work place which transfers ownership of the territory to those who work in it;
• The use of Daily Management as a lever for change and engagement as a vehicle to develop high performance teams.

This combination of theory and practice guides through the journey from passive to synchronous workplace design.

Understanding shop floor reality

• What does good look like?
• What are the wastes
• Why do they occur
• The management dilemma
• Control vs Engagement
• Understanding behaviours and engagement
• The principles of engagement
• The steps to high performing teamwork
• Understanding production processes
• Direct and indirect activities/standard work profile

Step 1: Take Control

• Assessing current design
• Understanding the shop floor reality
• Wastes, trouble map, priorities
• Standardisation
• Resilience and flexibility
• Clarifying normal conditions
• Coordination, feedback, skill levels
• Assessing visual management Information, Instructions, Knowledge
• Setting improvement measures and priorities

Step 2: Get organised

• Developing and refining layout options
• Task design and integration
• Material and information flows
• Training programme design and delivery.
• Improving daily management and Management/Team Standard work
• Developing and tracking the business case

Step 3: Get Better

• Engaging shop floor personnel
• Setting accountabilities, getting team engagement
• Reinforcing Change: tracking progress, giving recognition
• Raising Quality, Cost and Delivery performance
• Capture and resolve the causes of defects and human error
• Optimising working practices
• Develop a practical 90 day action plan
• Defining a realistic and achievable 12-month outcome
• Developing first step
• Delivering results

Review of the Workshop
Benefits, Concerns, Q&A

Led by Ian Weare of DAK Consulting

Ian's early career for a leading automotive component supplier included roles as engineer, team leader, manager and change agent. This has provided the practical foundations for his success as a coach and advisor to global industry leaders including BP, Coca Cola and Honda. He has developed a unique set of learning and skill development tools to explain difficult concepts whilst having fun. His challenging but supportive approach combines relevant theory with practical activities to develop insight and confidence to act.