Training and

Implementation
Introduction
•Training in lean manufacturing is the first step towards its implementation
in any organization.

•After identifying the training source, the management should make a

training plan and an implementation plan.
Steps involved in training and
implementation
• A lean champion has to be selected.
•Then lean leaders and learn associates are chosen.
•A meeting has to be called between the lean leaders and associates.
•The CEO of the organization has to explain the necessity of training and
implementation.
•A detailed training schedule in construction with the training source has to
prepared.
•The leaders and the associates have to be trained.
•Once the leaders and associates have been selected, brainstorming
sessions should be held where projects, that have to be implemented
are chosen.
•For each project the lean leaders have to be identified.
•Then the lean leaders select the associates for each of their projects.
•A project charter is prepared with the possible cost savings for each of
the project to the champion and get it approved.
 Steps involved in training and
implementation (Contd.)
• The lean leaders then prepare a detailed project plan.
• The leaders along with their associates have brainstorming sessions
where the plan for the projects is finalized.
• The next step is to commence with project implementation.
• At regular intervals it is important that the projects are reviewed.
• The savings done when implementing the projects should be calculated.
• The employees are then trained in 5S implementation.
• Once the employees are trained, implementation of 5S activity starts.
• The results of 5S are finally measured.

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Select the champion
• The lean champion should be very senior management employee who is
well-qualified and has worked in the organization for a period of time and
capable of motivating teams.

Responsibilities of the lean champion include

• Has visible leadership.
• Develop the strategy for lean manufacturing training and implementation of
the unit along with the training resource.
• Get financial approvals where required.
• Plan and organize training programmes.
• Plan cost savings and monitor.
• Plan key milestones.
• Keep the overall initiative on track.
• Inspire and promote lean culture.
Select lean leaders
The champion along with the departmental heads should select the lean
leaders based on the dossier prepared by the HR department and their
interaction with the candidates.
Responsibilities of lean leaders
• Prepare initial project assessment to validate benefits
• Lead and direct the team to execute projects.
• Determine the most effective tools to apply.
• Identify project resources.
• Report progress to the lean champion.
• Present the final report.
• Calculate project savings with the help of costing department.
• Ensure the results are sustained.
Select lean associates
Lean associates have to report, assist the lean leaders in the project team
and help them collect data, prepare process maps of current processes,
oversee the improvements planned, progress the work.

Responsibilities of lean associates

•Be part of the project team in carrying out lean projects.
•Help in preparation of the project plan.
•Participate in team meetings.
•Assist the team in process mapping the activities.
•Assist the shops/departments during project implementation.
•Oversee progress and report to the lean leaders.
•Carry out tasks allocated by the leader.
 CEO Meeting
• The main objective of this meeting is to introduce the subject of lean
manufacturing and make public the management decision to implement it
company wide.
Training Schedule
•The most important task is scheduling the trainings for the lean leaders,
associates, workers and staff.
•The lean champion after consulting the training resource and
departmental managers prepares a training schedule taking into
consideration of the availability of the participants.
•Non-responsive managers are appointed as lean leaders in order to
improve their performance.
A sample training schedule
Training lean leaders and lean
associates
•Prior to the training session the appointed consultant should know each
lean leaders and lean associates.
•The lean leaders and lean associates participating from various
departments later work in team to achieve the best results .

Lean leaders are given in-depth training in

•Lean manufacturing
•5 S workplace organization
•Process mapping
•Value stream mapping
•Cellular manufacture-plant layout
•Cause and effect diagram
•Brainstorming
•TPM
•The ten secondary lean tools
Training lean leaders and lean
associates
Lean associates are given in-depth training in
•Lean manufacturing
•5 S workplace organization
•Value stream mapping
•Cause and effect diagram
•Brainstorming

➢The training session should include visit of shop floor and other work
areas.
➢The training group should not be pressurized, the group should enjoy the
training and participate with enthusiasm and interactive.
➢The improvements attained will not be permanent unless the internal
resources are strengthened with full support and participation of the
employees.
 Brainstorming and selecting the
projects
➢Brainstorming sessions help identify problems an areas where wastes occur in the
company .
➢The brainstorming sessions are called by the champion .
➢The external consultant coordinate the brainstorming sessions with the
guidelines.
Brainstorming and selecting the
projects
In a brainstorming session hundreds of ideas will be put forward to meet
the customer requirement. However, it will not be possible to implement
all of them at a time.
In order to get the top 15 ideas, all should be put for voting by all the
participants.
Voting the ideas
➢The repeated and not connected ideas to the subject are discussed by the
group are sorted and eliminated .
➢The remaining ideas are recorded and considered for voting.

• The best method of prioritizing the ideas is Voting.

• Each member of the group rates the ideas recorded , in a covenant scale
and later ranks
• the ideas to choose the top 15 ideas for implementation and practice.
• Voting will ultimately help the organization to prioritize the projects.
Voting the ideas
Select the lean leaders for each
project
• The lean leader for a project is selected by the champion after much
deliberation mostly based on his area of specialization.
• The team leader will in turn select a cross functional team comprising
members from the department, related departments and one person
from a completely unconnected department.
• The purpose of the cross functional team is to make sure that the
aspects of the project are studied and improvements made.
 Prepare a project charter
A project charter has to be prepared and approved by the champion.
Once the champion approves the project charter, the lean leaders and his
team can start working on the project.

The project charter will have the following information.

 Prepare project plan
• The lean leader and his team has to prepare a detailed project plan listing all the
activities needed to carry out the project with regards to the data to be collected and
the time required to complete the task.
• Responsibilities should be designated to the associates in the team.
• The project plan should be practical and achievable.
• The lean leader shall get advice from the lean champion over the areas of concern
such as target date in the project charter etc.,
Prepare project plan Contd….
 Project implementation
• After collecting the data, the team should analyze the data and find a
solution to eliminate the waste.
• The solution can be found using any of the lean tools or a combination of
the tools.
• The solution should be discussed with the concerned departments and a
trial run organized.
• The team should be fully involved during the trial run and include any
suggestions/corrections given by the concerned department.
 Project review
• Any planned project needs to be reviewed regularly.
• During the meeting all aspects of the project plan is to be reviewed. If
there are any slippages, then the team must change the plan to make
good for the lost time.
• All success stories of projects should be well informed to all
employees of the organizations.
Project review
Calculate cost savings
• Lean manufacturing has to eliminate waste and improve
performance.
• As waste gets eliminated there is cost saving.
• All areas of improvement including those areas where measuring the
impact of lean manufacturing in terms of money is difficult.
• A cost accountant shall be hired to calculate the cost savings.
• Many companies have saved millions of dollars in a period of time by
lean manufacturing.
Training of employees - 5S
• Workers are an asset to any organization.
• In order to make them part of the lean implementation, it is
necessary that every employee an staff is given training programme
in 5S-shop floor organization.
• Since the employees are on the job and observe carefully, they
should be use to identify wastes this training on 5S will help them to
identify waste and provide ideas to eliminate the same.
5S implementation
• Implementation of 5S is the starting point for any company which is
adapting lean manufacturing.
• Abundant energy flows in the organization once the employees
complete the 5S training programme.
• 5S day shall be declared making all the employees to participate
with involvement.
Thank you