I was reading this discussion somewhere and thought that it makes sense to discuss it here. I like Lean concepts a lot and enjoy conducting lean sessions but I believe more than 2 days training sessions in Lean is just about over-complicating lean. Lean is about seeing waste, understanding waste and removing waste. Conceptually, lean is not complex. Implementation may be complex due to technology and culture issues.

Still I see consultants coming up with lean programs at different levels. Someone has proposed Lean Belts like Sigma Belts. Have consultants been over-complicating it?  I believe the beauty of lean lies in its simplicity and a Lean program need not be long (not more than 2 days). We are still contemplating an advanced Lean workshop but I am unclear about value it can deliver.

What do you think? 

Regards,

VK

Hi VK,

I believe, along with level of complexity of a pgm, its the participants prior exposure to quality and the structure that decide the length of any worshop. The various methodologies such as simulations, situations, exercises, practical examples etc used to deliver the training to make its participants understand the concepts at right pace plays an important role.

I have attended an inhouse 3 days Lean session followed by excecution of a project in 7 days time which further clarified the concepts. Concepts like little's law, hijunka, supermarket, work load balance, kanban card, associate chart etc needs some time to sink in.

An effective Lean workshop covering entire buquet of its tools and enabling participants to apply the philosophy, i think, just 2 days will not be sufficient.

 

Hi VK,

I go with Shalini view on this. The duration of the course is based the Target group. Some may be a new joiner, some with 5~10years experience & some beyond that. It all depends on how far the person is exposed to the Production & Quality systems.

Subgrouping of those cadres and conducting can give you an idea for deciding the course length.

Ram

Hi VK,

I am not in agreement for 3 days at all. 2 days should be adequate. This is because

a. Lean conducting on employees at entry level is a liability and waste of time. This is my opinion

b. if the partcipant is not aware of 5S principles, not through on inventory turns, Basic cycle time, Basic Tact time , Types of production ( Batch, Mass etc) , Type of flow (TPS), Process Mapping  etc even 3 days would not be effective

c) We should keep it simple not get into indepth details of each of the waste. The partcipants must be able to relate to the workplace

I am absolute in agreement of not complicating with green/black belts etc.

The production lines I worked were Motorola ( Pagers , 2 way radio& Phones) and A large US UPS Manufacturer . Both used single piece flow (TPS) and visual factory.

It was greek and latin when it was first thought to us. None of us were benefitted nor applied. We could get into the waste identification and elimination only after 2 years of operation and formal re launch of lean culture

Thanks