Top 10 Reasons to Attend:  1. We’ll show you how to make Lean self-funding. 2. We’ll discuss Lean from a practical perspective 3. You’ll learn how to cut operating costs by 20% or more 4. You’ll learn how to improve flow and cut lead times by 80% 5. You’ll learn how to eliminate unplanned downtime 6. We’ll discuss techniques for mass customization 7. We’ll look at achieving success in multishift operations 8. You’ll benchmark your cost/performance against the best 9. We’ll cover both basic and advanced Lean concepts 10. You’ll learn from others on the Lean journey Who Should Attend? Executives, plant/operations managers, plant supervisors and professionals from HR, Quality, Maintenance, Engineering and Training & Development will receive excellent value. In-House Training Successful implementation requires a team effort. Training as a team can help accelerate change and elicit plant-wide involvement. Granite Bay can bring Successfully Implementing Lean Manufacturing to your facility, custom-tailored for your organization. To schedule this seminar at in house or for rates and information, click here or call us at (916) 797-2263. Tuition and Registration Please call or email for in-house rates.		Lean Shift Operations Tools, tips and techniques for implemenmting Lean Manufacturing principles in a multishift environment Don Penkala Seminar Leader   Past attendees: AlliedSignal Bausch & Lomb Benjamin Moore BF Goodrich BP Bristol Myers Squibb ChevronTexaco Colgate-Palmolive DHL DuPont Electrolux GE Kimberly-Clark Kraft Foods Miller Brewing Motorola Nabisco NEC Nestle Northrup Grumman Ocean Spray Owens-Corning P&G Rayovac Sara Lee Sony TDK Texas Instruments Toshiba Toyota TRW Unilever US Postal Service Yamaha Competitive global cost pressures and increasing demands from customers are forcing manufacturers to build products faster, better and cheaper and to continually improve the way they do business. Through successful implementation of Lean Manufacturing, many plants have slashed unit costs by a third, quality defects by two-thirds and lead times by up to 90%. But becoming lean in a multi-shift environment poses some serious challenges. We'll not only cover Lean tools and proven cost reduction strategies, but also how to implement them successfully while engaging the entire organization. Unlike other Lean seminars that cover just the basics and tout Lean as a "magic pill", this session is about the "nuts and bolts" of how to make it work. And we'll discuss some more advanced Lean concepts for those familiar with the basics. We will lay the groundwork for those looking to start a Lean initiative, as well as for those who need to retool their current approach. Operating multiple shifts can be like running several different companies at the same time. Each shift change brings a different plant culture and often, different objectives. But your customers are demanding lower costs, higher quality and quicker delivery. Good coordination and collaboration are needed. You cannot afford to be Lean only from 8 to 5; you need to leverage your entire organization to deliver sustainable, continuous improvements. This two-day seminar is designed for plant leaders looking to give their plants a competitive edge by executing lean strategies across all shifts. It provides a comprehensive, yet detailed overview of Lean principles, while addressing the unique issues faced by multishift operations. Whether you’re looking to streamline operations 24/7, eliminate costly manufacturing waste or promote teamwork and communication, this seminar will provide practical, proven solutions. Have your team join us and learn how to deliver products faster, better and cheaper, while improving employee morale. Seminar Outline Request a detailed outline and brochure Day 1 1. 1. 24/7 Operations: Necessary Evil or Competitive Advantage? Using shift operations for competitive advantage Building a cohesive plant unit The 5 Cs of world-class shift operations Common mistakes in 24-hour management Benchmark performance from world-class plants Group Activity - Self-Assessment: How does your plant measure up?   2. Achieving Seamless Flow Identify the hidden inefficiencies that cost millions How seamless operations reduce key costs How to increase plant capacity with zero hiring & capital investment How to increase productivity by 9% immediately Link daily production with daily demand Balance operations on and across shifts Balance equipment utilization and lead time Improve equipment uptime & process reliability Group activity - Slash lead times and increase utilization of bottleneck processes   3. Scheduling People and Processes   Why most shift schedules are cost-inefficient Key considerations in shift schedule design Examples of 8-, 10- & 12-hour schedules 8s, 10s & 12s: pros and cons for managers and employees Fixed or rotating shifts - which is best? Design & implement a “lean” shift schedule Group Activity - How Lean is your current schedule?   4. 24/7 Communications to Support Lean How effective communication increases productivity Communication strategies to improve flow and reduce work-in-process The 3 keys to effective management communications The 4 keys to effective team communications Best practices in cross-shift communications - tools, participation, agenda & scheduling Group Activity - Redesign a plant’s 24/7 communication strategy 5. Building a High-Performance Work Force Engage the entire work force Implement cross-shift cells and teams Strategies for building cross-shift interfaces 3 approaches to plant-wide continuous improvement (inlcuding 24/7 Kaizen) Standardize processes & procedures across all shifts Group Activity - Revitalize a plant’s performance management strategy   6. Providing effective 24/7 Leadership Create a lean organizational structure Shift supervisors or process managers - which are more effective? Develop “value-added” leaders on the plant floor Proven methods for reducing “fire-fighting” Group Activity - Assess and improve a plant’s leadership effectiveness   7. Creating & Supporting a Lean Culture 24/7 How to determine the ideal shift staffing level Training tips & strategies for multishift operations Essential support requirements for the late shifts Recruiting and retaining quality employees for shift work Group Activity - Create a roadmap for improvement at your facility Day 2 4. Making Processes Flow 5. Developing an Effective Pull System 6. Improving Process Reliability with RCM and TPM Day 3 7. Quality Tools to Support Lean 8. Leading Cost Reduction through Lean Past attendees say... “Great session! Light on theory and heavy on practicality.” - Operations Manager, Electronics Co. "Excellent. Content was flexible enough to meet the needs of the group. Well worth the investment of time and money.” - Operations Manager, Metal Finishing Co. "I felt what we had at our plant was the best. This really opened my eyes to new possibilities.” - Plant Manager, Food Products Mfr.
	GRANITE BAY GLOBAL - 916-797-2263 - email P.O. Box 2514, Granite Bay, California 95746 USA The material on this web site is copyright ©1997-2012 by Granite Bay Global, Inc.