Lean Manufacturing Event Planning Guide Introduction

This document is intended to assist in planning and executing a implementation event for Lean Manufacturing. Where differences exist in the two event types (Implementation or Educational), specific notes have been added “IMP Only” or “EDU Only”. A Checklist of Preparation Activity Items is listed on the next pages in sequential order. The GANTT Chart shows the activity items with appropriate duration needed to complete each task prior to event. Details for each of the activity items are included in the Planning Guide sections that follow.

The first column indicates the appendix where information or contact personnel are available. The next columns list the person(s) ultimately responsible for the completion of each item; however, other individuals may be required to provide the necessary information or input.  Appendix sections include necessary worksheets, wall charts, process flow and layout examples, etc.

1

consultant. instructors & champion X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Lean Manufacturing Event Planning Guide Implementation Preparation Activity Checklist C H A 2 C H A M F A A S C C O O .Lean Manufacturing Event Planning Guide Implementation Preparation Activity Checklist C H A M P I O N C H A N G E A G E N T M A S T E R F A C F A C I L I T A T O R C O O R D I N A T O R # ACTIVITY ITEMS NAME TARGET DATE FINISH DATE 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Decide to have event Select master facilitator Prep master facilitator for planning event Select added facilitators & instructors for presentations Select event coordinators Review event requirements Select classroom Select break-out rooms (one or two) Determine event date Develop preparation activity checklist Prep event coordinators Select lean consultant Determine site to be subject of event Create list of desired participants and prioritize names Review activities with organization’s leadership Review worksite and objectives with consultant Prepare worksite package for event participants Prepare worksite facts and layout sheet Develop event content Develop agenda Select breakfast. lunch and break rooms Prepare planning guides and speakers notes manuals Distribute speakers notes to instructors Distribute facilitators guides to facilitators Confirm event package Secure classroom layout Secure classroom equipment Secure Equipment for breakout rooms Determine trades/special equipment requirements Secure special equipment needed Review event plans with target worksite personnel Prep facilitators/master fac. For conducting event Prep change agent.

ACTIVITY ITEMS # M P I O N N G E A G E N T T E R F A C I L I T A T O R R D I N A T O R NAME TARGET DATE FINISH DATE 34 35 36 37 38 39 40 41 42 44 45 46 47 48 49 50 Review worksite and worksite packages Establish phone procedure and location for messages Secure educational material and exercise forms Order and obtain event supplies Select worksite guide(s) (operator in worksite area) Provide wall charts and value stream maps Prep worksite guides for initial worksite visit Review event visit times with worksite personnel Dry run for instructors. champion and change agent Confirm visitor attendance Place directional arrows in halls and in plant Final preparedness check File report-out data for future implementation reviews Review assessment comments Conduct daily wrap-up meeting on all shifts (ongoing) Provide event manuals (optional) X X X X X X X X X X X X X X X X X X X X X X X X X X X Lean Manufacturing Event Planning Guide Implementation GANTT Chart ACTIVITY ITEM # 12 11 10 09 08 07 06 05 04 03 02 01 00 WEEKS PRIOR TO EVENT 01 Decide to have event 3 .

02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Select master facilitator Prep master facilitator for planning event Select team facilitators and instructors for presentations Select event coordinators Review event requirements Select classroom Select break-out rooms for teams (one or two) Determine event date Develop preparation activity checklist Prep event coordinators Select lean consultant Determine site to be subject of event Create list of desired participants and prioritize names Review activities with organization’s leadership Review worksite and objectives with consultant Prepare worksite package for event participants Prepare worksite facts and layout sheet Develop event content Develop agenda Select breakfast. for conducting event Prep change agent. instructors & champion Review worksite and worksite packages Establish phone procedure and location for messages Secure educational material and exercise forms Order and obtain event supplies 4 . consultant. lunch and break rooms Prepare planning guides and speakers notes manuals Distribute speakers notes to instructors Distribute facilitators guides to facilitators Confirm event package Secure classroom layout Secure classroom equipment Secure equipment for breakout room Determine trades/special equipment requirements Secure special equipment needed Review event plans with targeted worksite personnel Prep facilitators/master fac.

Lean Manufacturing Event Planning Guide Implementation GANTT Chart # ACTIVITY ITEM 12 11 10 WEEKS PRIOR TO EVENT 09 08 07 06 05 04 03 02 01 00 38 39 40 41 42 43 44 45 46 47 48 49 50 Select worksite guide(s) (operator in worksite area) Provide wall charts and value stream maps Prep worksites for initial event visit Review event visit times with worksite personnel Dry run for instructors. champion and change agent Prep cafeteria manager ( if lunch room exercise is on) Confirm visitor attendance Place directional arrows in halls and in plant Final preparedness check File report-out data for future implementation reviews Review assessment comments Conduct daily wrap-up meeting on all shifts Provide event manuals (optional) 5 .

Coordinators must be available to support the master facilitator before. Generally. Instructor Four MODULE 6: Pulling It Together. the use of the consultant is not recommended in that they would not be part of the plant leadership team. Provide a copy and review entire planning guide. X X X X X 6 . as observers. to become familiar with the process. Select master facilitator. it is strongly suggested that they have attended at least one lean implementation manufacturing event in its entirety. Facilitators. The champion of an organization will determine the need for a lean implementation Event. coordinate. MODULE 1: Introduction. Coordinators are responsible for the classroom. until all follow-up work is complete. and facilitate the event.Lean Manufacturing Event Planning Guide Implementation Checklist Details RESPONSIBILITY A C C M F C P H H A A O P A A S C O E M N T I R N P G E L D D I E R I I I O T N X N A F A A G A T T E C O O N R R T X X # ACTIVITY ITEMS DETAILS 01 02 03 04 05 Decide to have event. should be utilized to facilitate the lean implementation event activity. They should plan to be present for the event. and for the full day of set-up. Champion Instructors should be recognized as leaders and hold leadership positions within the plant. The role of the master facilitator will be to work with the champion and the plant leadership to plan. Champion MODULE 2: Identification of Waste. Has good organizational skills and good facilitation skills. one coordinator is needed beginning two weeks prior to and continuing through the event and beyond.one or two individuals. the change agent. However. Education Theory. Lean Manufacturing . Road Map & Next Steps. Measurement Explanation. Can use instructors who teach modules above. Master Facilitator MODULE 6: Implementation Exercise. They should have attended at least one implementation event. Lean Implementation Review. They should have attended at least one event. Select facilitators and instructors for presentations and exercises of event content. Instructor Two MODULE 4: Pull System. champion and the lean consultant maybe used as instructors. Can appropriately utilize the organization’s resources to prepare for the event. Additionally. Select event coordinators. and have been on a visioning trip with their champion. Obstacle Review. The champion should fully discuss this event with all leadership and involved personnel to ensure the necessary process support to implement a event is available. Prep master facilitator for planning event. break-out rooms and worksites. Change Agent MODULE 1: Why Are We Here. during and after the event. Additionally. Instructor One MODULE 3: Value Stream Mapping & Elimination of Waste. Requirements: Has previously attended a lean implementation manufacturing event in its entirety. Instructor Three MODULE 5: Workplace Organization & Visual Controls.

: production operators. Arrangements should be made to ensure that all rooms can be opened by the facilitators. Select lean consultant.Lean Manufacturing Event Planning Guide Implementation Checklist Details RESPONSIBILITY A C C M F C P H H A A O P A A S C O E M N T I R N P G E L D D I E R I I I O T N X N A F A A G A T T E C O O N R R T X X # ACTIVITY ITEMS DETAILS 06 07 08 09 10 11 12 Review event requirements The champion should fully discuss all elements of the proposed event with all leadership and involved personnel to ensure the necessary process support is available. These personnel must be available at times indicated in the planning guide and agenda. Room needs to have good ventilation. It is imperative the master facilitator secures a classroom of appropriate size. During exercises. The selected consultant must be conversant with all elements of lean transformation with personnel experience with large scale lean manufacturing implementation. it is pivotal that the consultant fully support Parker Hannifin’s lean enterprise initiatives. ventilation. Prep event coordinators. etc. sufficient work must be visible (worksite locations must be operating) to allow participants the opportunity to discover. Prerequisite: Champion.e. facilitators. Refer to pages 3 through 6 in the lean manufacturing event planning guide to plan and coordinate all events. Dry Run: Champion and event staff will dry run all teaching modules as outlined in item #42. facilitator. privacy. Break-out rooms should be located within close proximity of the classroom and/or worksite(s). It is essential that the lean consultant provide support for the concepts taught in the lean manufacturing events. facilitators and coordinators should have assisted in their roles at a previous event. and lighting and sufficient wall space for wall charts Select break-out (0ne or two) rooms. Moreover. change agent. He will support the concepts that are being presented with his comments. The change agent should be in the classroom during all presentations. acoustics. acoustics. coordinators and key worksite personnel comprise the personnel responsible for the conduct of the lean manufacturing events.). headquarters personnel. Master facilitator. Resources: Champion. Classroom and Break-Out Rooms: Must be available as outlined in items #7 and #8. change agent and staff should have attended a previous lean manufacturing event in its entirety. The room needs to have good projection equipment. security. screen. Location: The event location should be selected based on whom the event is supporting (i. and a visitor to sit around a table. Attendance: is required for the champion. event staff and all participants for the whole event. lighting and large enough for all participants. Select classroom. to emphasize the importance of the concepts. preferably the same event. Visioning Trip: Champion should where possible take event staff and participants on an appropriate visioning trip(s) where the lean manufacturing principles can be seen. Determine event date. When event requirements can be completed and resources are available. Sufficient room to hang wall charts. Assign tasks to coordinators based on timing and responsibilities plan. He will visit worksites and break-out rooms to ensure the process is being followed and supported by his staff and participants. X X X X X X 7 . change agent. master facilitator. Develop preparation activity checklist for timing and responsibilities. instructors.

H. pull signals. Worksites must have identifiable input(s) and output and the process flow must be trackable. Pull System: Inventory levels. finance. improved work. F. etc. they will cascade this knowledge by becoming an instructor/facilitator at the next level event for their organization. decoupled process. Review with organization’s leadership. Identification of Waste: 7 Types. Worksite must have more than one (1) customer/supplier relationship (i. Participants maximize their understanding by “doing” and “discovering” the potential for concepts presented. lot size and containerization. E. engineering. process). personnel. It should address a key business need or needs to include safety. Worksite must be operating (all three shifts. etc. Finally. D. marketing. These criteria should be on a value added or cash flow basis. 5. G. X X X X X X 8 . Event intent is to educate by experiential learning. Selection and preparation of the worksite is critical and . the following criteria must be met: A. Review worksites and objectives with consultant. delivery performance. standardized systems. Preliminary worksites criteria selection should be reviewed with staff and with all other appropriate parties prior to making final determination. inventory reduction and capital avoidance. B. if necessary).place organization. It would be desirable to select a worksite that demonstrates the concepts (or lack of) taught in order to enhance the learning experience for all participants (opportunities for improvement). process/operator controls. Review the intent of the event. C. the generic agenda and attendees with the staff and all other relevant and interested parties. material. The site selection must be based upon specific criteria. Participants should be included from all disciplines of an organization: manufacturing. 3 contributors. Further. the selected site should offer great potential for improvement in multiple areas of lean manufacturing to include a 30% improvement in productivity. Elimination of Waste: Flow of a part through a number of process steps (store. preventative maintenance. Process must not be so large that the participants can not comprehend it during the worksite review and also must not be so small that it does not challenge the participants.: internal . scrap. Once they have “graduated”. visual control and supply chain compression etc. 3 Process or processes capable of being summarized by a value stream map. etc. an implementation event should always be done in an area of high visibility in order to further promote lean implementation on a plant wide basis. Create a list of desired participants and prioritize names. boundary samples. Workplace Organization and Visual Controls: Flexible systems. a 30% reduction in inventory. etc. variation.). purchasing. and the supplier community to provide a broad base of experience. handle. 1. profitability. customer satisfaction or quality. 2. Must be mutually acceptable to management and union (if represented).external. inspect. therefore. 4.Lean Manufacturing Event Planning Guide Implementation Checklist Details RESPONSIBILITY A C C M F C P H H A A O P A A S C O E M N T I R N P G E L D D I E R I I I O T N X N A F A A G A T T E C O O N R R T X X # ACTIVITY ITEMS DETAILS 13 14 15 16 Determine the Site to be the event subject.e. problem prevention (error proofing devices). Worksite personnel must be approachable and cooperative. Key worksite personnel must be available during the entire event.

The worksite package consists of a worksite facts and layout sheet that graphically depicts who the worksite personnel are and their respective locations. See and Do). Examples and illustrations may vary slightly depending on the specific needs of participants. Select breakfast. the process will be made visible with the process flow block diagramed and value stream maps that graphically depicts the process at a macro level and highlights the sections of the process to be reviewed . Develop event content. Include in attendees folder. Event start and stop times. necessary to do a complete event. Develop agenda . Master facilitator will review the agenda of module timing for “hear” concepts. the champion. These measurements are to include but are not limited to productivity improvements. Distribute facilitator’s guide and agenda to facilitators. worksites. by champion and participants. Layout will include column numbers.Lean Manufacturing Event Planning Guide Implementation Checklist Details RESPONSIBILITY A C C M F C P H H A A O P A A S C O E M N T I R N P G E L D D I E R I I I O T N X N A F A A G A T T E C O O N R R T 5 X X # ACTIVITY ITEMS DETAILS 17 18 19 20 21 22 23 24 Prepare worksite package for event participants. and facilities. breaks. personnel locations. bathrooms. Agenda for the event must be fully supportive of the intent of the event. posted on wall charts throughout the course of the event. maintain a master file of all documents for subsequent events. agenda events and timing. (in modules one or six only) he is responsible for its development. Must be large enough to allow all participants to sit down at the same time. phones. quality improvements. Include on layout: parking lot. MODULE 6 Process Measurement . the training modules must relate to the actions and desired outcome anticipated for the event. X X X X X X X X X X 9 . and delivery improvements. inventory reductions. break-out rooms. recognizing the Companies initiatives will establish the specific measures for each event. It includes text. and “do” reportout times with each instructor. equipment outlines. “see” opportunities. Rooms should be close to the classroom to reduce travel lead time. Module content has been established by the champion and the change agent. facilitators guide for facilitators and appropriate sections of speakers notes for instructors (including champion and master facilitator). NOTE: Implementation Event Only. safety improvements. MODULE 6 “Clearing the Path” Exercise: Involves discussion of obstacles and points to be revisited. Instructors will make known the module contents and time requirements. entry/exit. Generally. In other words. conveyors. This layout should show how to get from the lobby to the classroom. Distribute instructor’s speakers notes and agenda to each instructor. north arrow. cafeteria. lunch and break rooms. emergency exits. . Obtain and prepare planning guides and speaker notes manuals for appropriate personnel. takt and cycle time must be readily available. and lunch will need to be coordinated with headquarters or plant production start and stop times. product flow arrows and boundaries of worksite. Obtain facilitators guide from the planning guide and provide a copy to each facilitator. If there is only a single lunch room than a portion of the lunch room can be set aside for the event during the planned lunch periods. Facilitators and master facilitator are to familiarize themselves with the exercise contents and agenda time requirements for all exercise activities. classroom. Modules can not be split between two days. Establish specific process measurements that will reflect the organizations performance relative to implementation of lean. Prepare worksite facts and layout sheet for worksite and classroom. transparencies. breaks and lunch. (Hear. Run copies of the planning guide for master facilitators and coordinators. Additionally. “do” break-outs. If the champion wants additional supportive information.

It is critical that they are not only knowledgeable about the event but are supportive of the activity as well. Prep facilitators and master facilitator. Secure special equipment. portable welding equipment etc. the event from a design standpoint is frozen. as a minimum. The rooms selected must comply with the requirements identified in item #7 and #8 of the Event Planning Guide. change agent and consultant should review the package to confirm that the agenda and related exercises are consistent with event intent. Prep instructors. markers etc. as a minimum. Secure equipment for break-out room. Now that the event design and intent are finalized. Secure classroom equipment. the instructors from that event should prep the new instructors. Instructors must be interactive. master facilitator. The maintenance equipment would include mobile cranes. These measures cannot be so obvious as to give the participants the impression that the leadership team already has the final answer. screen and audience to provide variety to the delivery and adjust pace of delivery. consistent with item #7.. The master facilitator should ensure that the necessary special equipment such as video equipment and maintenance equipment is available for the required times during the event. then appropriate countermeasures must be taken. From this point forward. X X 28 29 X X 30 31 X X X 32 33 X X 34 X X 10 . The champion and the change agent must review the event in its entirety with targeted worksite personnel on all affected shifts. Review content of each slide for understanding. If these needs cannot be funded internally. illustrate concepts with brief. secure the required rooms based on both size and timing of event. move between the overhead projector. as required. ask questions when appropriate.Lean Manufacturing Event Planning Guide Implementation Checklist Details RESPONSIBILITY A C C M F C P H H A A O P A A S C O E M N T I R N P G E L D D I E R I I I O T N X N A F A A G A T T E C O O N R R T X X X # ACTIVITY ITEMS DETAILS 25 26 27 Confirm event package The champion. Review worksites and worksite packages. NOTE: If the organization has had a previous event. Secure class and break-out rooms. champion and consultant. The coordinator should secure all required breakout room equipment for the event. The required equipment should be. The change agent should conduct a brief walk through with both the master facilitator and the coordinators. Additionally. Determine skilled trades/maintenance equipment requirements. the change agent and maintenance leadership must anticipate maintenance needs from both a physical and human resource needs perspective. The required equipment should be. Review with the facilitator and master facilitator their roles during the event. The coordinator should secure all required classroom equipment for the event. Any change following this step must be approved by the champion. easels. Once the scope and intent of the event is confirmed and finalized in item #25. determine where are to be placed and disposed of. if coffee and/or rolls are to be provided. to complete the presentation on time. Master facilitator (with the coordinator) reviews the worksite package with the facilitator and also visits the worksite to introduce facilitator to the worksite personnel. Review event plans with targeted worksite personnel. Worksite personnel should review all fact sheets and value stream maps that are part of the event. personal experiences that the participants can relate to. consistent with item #8 and should include the necessary markers. easel paper.

time and any special dietary requirements. Event Slides: Coordinator will run black and white transparencies from master copy or color transparencies if original files are available on disk and put in frames. etc. Provide wall charts and value stream maps exercise. Worksite guides must be present during these visits. supervisor. instructors. master facilitator and champion. Enlarged value stream maps are to be placed on the walls in both the classroom and all breakout rooms. Prep Cafeteria Manager. brief explanation and tour of area. introductions. then the master facilitator must ensure that the lunch room manager is aware of the number of people. Review event visit times with worksite personnel. If. and master facilitator to ensure that everyone is familiar with each module and can be supportive of the event. Exercise forms 8 1/2” x 11” are used for team break-out and report-out activities. Mercury Marine. Select worksite guides. 2nd visit Pull System and 3rd visit Workplace Organization and Visual Controls. Send out a letter to The event timing as it relates to the worksite visits must be reviewed with worksite personnel to ensure that the worksite is operating normally during the agenda scheduled visit times. X X X X X X X X X X X X Lean Manufacturing Event Planning Guide IMPLEMENTATION Checklist Details A P 11 RESPONSIBILITY C C M F C H H A A O . Enlarge classroom and break-out rooms wall charts to 24” x 32” and laminate for protection to allow for writing on charts with water-based markers for on-going events. The instructors must do a complete dry run as if they were giving it to the live audience so they are comfortable with their content. Further. Welcome.D. timing and roles. Questions posed to the operators should not interfere with their work. Contact the Lean Support Team for the following material. The dry run audience should include the champion. The change agent should confirm the attendance of any visitors and ensure that they have designated parking and have the proper attire for worksite visitation. Lastly. Caution that the primary purpose of the area is to make quality products. the cafeteria will be responsible for same. Prep worksite and worksite guides for initial worksite visit. If the optional lunch room exercise is on. coffee is served. all messages will be posted on the message board. make copies as needed. . Order and obtain color-coded event supplies. safety precautions. Confirm visitor attendance. the buffet style lunch must be organized the first day and disorganized the second day. Dry run for instructors. master facilitator must ensure that video is properly setup for first and second day lunch room exercise. Waste and Value Stream Map.Lean Manufacturing Event Planning Guide IMPLEMENTATION Checklist Details RESPONSIBILITY A C C M F C P H H A A O P A A S C O E M N T I R N P G E L D D I E R I I I O T N X N A F A A G A T T E C O O N R R T X 4 X X # ACTIVITY ITEMS DETAILS 35 36 37 38 39 40 41 42 43 44 Determine requirement and location of telephones and message board. The coordinator is responsible for having a sufficient supply of material on hand at the time required. Newspaper Articles: articles out of newspaper or magazines related to business. Location should be outside the classroom to avoid interruption Secure educational material. Unless it is an emergency. etc. Any significant points of interest. Review agenda timing “See” Opportunities: 1st visit I. Build 4 Hour House. Video tapes: Discovering the Future Paradigm Tape. change agent. This should be someone familiar with worksite area (operator. The coordinator’s responsibility is to arrange for the acquisition and replenishment of necessary supplies. Guide should be available for questions during all of the exercise “See” times. All the necessary material and supplies required for a event will be inventoried by the coordinator in one central location.).

change agent. coordinator and the consultant. the assessments from the event should be reviewed by the champion. breakout rooms or the parking lot. Provide event manuals. This feedback should be used to adjust current and future events as part of an ongoing continuous improvement process. This file must be standardized to facilitate monitoring by plant and Corporate personnel. master facilitator. Review assessment comments. the report must be file in a manner that would facilitate progress monitoring on a department or product basis over time. Final preparedness check. X X X X X X X X X X X X 12 . The change agent and the master facilitator must develop a file to record and monitor performance data for each event. lunchroom. The coordinator should ensure that sufficient directional arrows are in the facility to ensure that all participants can easily move from the classroom to the worksite. the change agent and/or the champion should conduct an all hands meeting on each shift in order to ensure that all employees are aware of the event. This final check may include a final dry run if required in the opinion of the champion. Care must be taken to listen carefully to the observations of those employee who are not participants in the event. Daily. File report-out data for future reviews. This activity is optional and is left to the discretion of the champion. Champion and the change agent must conduct a final preparedness check to ensure the plant is completely ready for the upcoming event. facilitator. Conduct daily wrap-up meeting on all shifts Daily. bathrooms. Further.# ACTIVITY ITEMS DETAILS P E N D I X A M P I O N A N G E A G E N T S T E R F A C C I L I T A T O R O R D I N A T O R X 45 46 47 48 49 50 Place directional arrows in halls and plant.

13 .

Sign up to vote on this title
UsefulNot useful