STAUFEN. Lean Expert Program EN

TRAINING PROGRAMS

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Within the scope of our training programs, we use a targeted approach that enables you to specifically expand your specialist and leadership skills.

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TRAINING PROGRAMS

08 Lean expert and Lean trainer training

10

Basic training to become a lean expert

11

Lean development

12

Lean manufacturing

13

Lean assembly (large scale)

14

Lean assembly (small scale)

Lean order fulfillment

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16

Lean administration

17

Lean purchasing

18

Lean logistics

19

Lean construction

20

Top-up training to become a lean trainer

22 Six Sigma training

24 Lean Six Sigma training

26 Kata training

28 Lean Leader training

32 Executive Leadership program

TRAINING PROGRAMS

7

Lean expert and lean trainer training

INVEST TODAY IN THE FUTURE OF YOUR LEAN EXPERTISE. With your own in-house improvement experts, you can establish the best prerequisites for consistently utilizing your optimization potential. Our training programs are

TRAINING PROGRAMS

8

LEAN EXPERT AND LEAN TRAINER

not only effective and professional, they are also held at eye level and with respect for everyone taking part. In the same way, our graduates can also go on to convey their expertise to you internally and support your improvement process with on-site

After successfully completing stage

workshops and projects.

1 and stage 2, you will receive your

Our three-stage training is both recommended and certified by the Institute for

"lean expert" certificate.

Production Management, Technology and Machine Tools (PTW) at

After successfully completing stages

the Technical University of Darmstadt.

1, 2 and 3, you will receive your "lean trainer" certificate.

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OUR PROGRAM STAGE 1: As an aspiring lean expert and trainer, you actively improve your communication and moderating expertise, as well as the skill to successfully plan and hold

LEAN EXPERT AND LEAN TRAINER TRAINING PROGRAMS

workshops.

STAGE 2: You build on your knowledge in your respective field. Beside "knowing", the highly practical focus also guarantees that you gain the ability to apply the knowledge.

Prior knowledge of lean concepts is required.

STAGE 3: As an aspiring lean trainer, you learn, "how can I teach others something?" rather than "how can I apply something myself?" based on the Train-the-Trainer concept.

STAGE 1

STAGE 2

Compulsory course

Compulsory course

RECOMMEN­DATION (not part of the training)

BASIC TRAINING

SPECIALIST ­ TRAINING

PRACTICAL

Lean basics and workshop work

Specific specialist knowledge and application of methods

Workshops and projects

APPLICATION

Exami­ nation Lean Expert Seminar: »» Basic training as a lean expert (p. 10)

Seminar: Select at least one course depending on the areas in which you wish to receive advanced training: For series manufacturers: »» Lean manufacturing (p. 12) »» Large-scale lean assembly (p. 13) »» Lean logistics (p. 18) For individual-/small-series ­manufacturers:

»» Small-scale lean assembly (p. 14) »» Lean order fulfillment (p. 15)

STAGE 3 Optional course

TOP-UP TRAINING Increasing teaching and organizational skills

Exami­ nation Lean Trainer Practical ­application: Before starting stage 3, you should first apply what you have learned in projects in your own environment.

Our trainers will be happy to support you here, if necessary.

Seminar: »» Top-up training to become a lean trainer (p. 20)

For the construction industry »» Lean construction (p. 19) Irrespective of industry/ manufacturing type: »» Lean development (p. 11) »» Lean administration (p. 16) »» Lean purchasing (p. 17) << CONTENTS

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STAGE 1

Basic training as a lean expert

TRAINING PROGRAMS

LEAN EXPERT AND LEAN TRAINER

Lean basics and successful workshop work

VISI

WHY? Your task as an aspiring lean expert is to plan and successfully design the CIP. At the same time, however, you also have to be capable of managing teams efficiently.

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FOR WHOM? Aspiring improvement experts from direct and indirect company departments

It therefore makes sense that the early part of your training will teach you how to handle conflicts and demotivation in the phases of lean transformation, since being able to professionally handle stumbling blocks during the change process is very important and should not be neglected. As part of this first stage of training, you will therefore gain the necessary basic knowledge on designing low-waste processes and the basics of CIPs. You will also develop your soft skills, such as the moderation and presentation techniques required to organize and run CIP workshops correctly.

HOW? Our approach to training places great emphasis on implementing what has been learned. Beside conveying knowledge of the basics, team work and practical exercises represent a key component of the training. You will draw up and give structured CIP presentations and then receive individual feedback for your personal further development. Learn from experts from a wide range of industries and company structures.

WHAT? »» The basics of lean processes, problem solving and analysis tools »» Just-in-time simulation for practical experience of the lean principles »» Structure, necessary activities and role of the CIP office »» Duties, areas of expertise and responsibilities as a lean expert »» Controlling social processes and effective work in teams »» Success factors and methods for planning and hosting CIP workshops

5 DAYS EUR 2790 / CHF 3240

»» Giving and receiving effective feedback »» Reflecting on your own role »» Successful project planning in a 12-week design and drawing up a personal activity plan

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STAGE 2

Lean development

VISI

WHY? Innovation and product development are core competencies that are playing an increasingly important role in securing a company's economic success. Only those companies that succeed in fulfilling client requirements in terms of throughput times,

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FOR WHOM? Aspiring improvement experts, as well as (junior) executives from R&D, Design, Project Management and Lean/CIP

LEAN EXPERT AND LEAN TRAINER TRAINING PROGRAMS

Methods for lean development

budgets and qualitative results will be able to secure long-term competitive advantages. At the same time, a lack of waste awareness in development departments means that there are still huge, untapped improvement opportunities with regard to effectiveness and efficiency. In this stage of training, you will learn about how the application of lean criteria can also lead to a significant improvement to the project objectives of development departments, such as project completion times and budgets.

HOW? The focus is on successfully applying lean management to accelerate product development. Through practical examples, simulations and theoretical input, you will learn about methods and tools for describing a lean development system independently. Learn what management efficiency through transparency means, and draw up your own personal activity plan. Benefit from mingling with expert colleagues from a wide range of industries and company structures.

WHAT? »» The basics of lean management in the context of lean development »» Business game: Adding value and minimizing waste when introducing a new product »» Duties, areas of expertise and responsibilities in the development project »» Innovation and development roadmaps for transparent management and error avoidance

5 DAYS

»» Planning, analyzing and successfully implementing a change project

EUR 2890 / CHF 3290

»» Critical-chain project management, reducing project processing time and ­delivering on time

INCL. WEB-BASED TRAINING "LEAN BASICS" BEFORE STARTING TRAINING

»» Product design in line with lean principles »» Management efficiency in R&D through visualization, Shop Floor Management and project prioritization »» Plus: Final test to confirm content has been understood << CONTENTS

WEB CODE: www.staufen.ag/DE-168

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STAGE 2

Lean manufacturing

TRAINING PROGRAMS

LEAN EXPERT AND LEAN TRAINER

Methods for lean manufacturing

VISI

WHY? Put an end to long processing times, high inventory levels, unplanned machine downtimes and quality fluctuations. Together with SEW-EURODRIVE, we offer you an effective training concept that will help you break out of conventional ways of thinking. Optimize your manufacturing processes sustainably and with value stream ori-

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FOR WHOM? Aspiring improvement experts, production managers, schedulers, supervisors, team and group leaders, as well as (junior) executives from Production/AV and Lean/CIP

entation. You will learn about the principles of standardized, stable production processes, as well as the effects they have on your daily work. Experience improvement management based on the example of WIEPRO Consulting. The learning-by-doing concept allows you to establish excellent manufacturing processes – first at the BestPractice plant of SEW and then in your own works environment.

HOW? You will learn in detail about lean methods and tools in the context of lean manufacturing and expand your knowledge through business games, practical workshops and results presentations. The SEW shop floor offers a practical visualization of the theory. This experience will encourage you first to recognize potential and then bring it out in a structured way at your own company. Take the opportunity to mingle with expert colleagues from a wide range of industries and company structures.

WHAT? »» The basics of lean management in the context of lean manufacturing »» Just-in-time simulation, from job-shop manufacturing through to the process chain »» Independent value stream analysis, value stream design and layout planning »» One-piece-flow in machining operations »» Sequential production in chaku-chaku cells »» TPM and Muda check to ensure there are no malfunctions or waste »» Independent changeover time optimization with SMED

5 DAYS EUR 2890 INCL. WEB-BASED TRAINING "LEAN BASICS" BEFORE STARTING TRAINING

»» Technology optimization for machining processes »» Plus: Final test to confirm content has been understood

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STAGE 2

Lean assembly

VISI

WHY? Do you know the problems with long lead times, missing flow principles in the assembly cells, material buffers between the work stations, large batches and non-synchronous work processes? This training will help you break out of conventional ways of thinking and sustainably optimize your assembly processes. The focus is on rec-

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FOR WHOM? Aspiring improvement experts, production managers, schedulers, supervisors, team and group leaders, as well as (junior) executives from Production/AV

LEAN EXPERT AND LEAN TRAINER TRAINING PROGRAMS

Methods for lean assembly (large-scale)

ognizing and bringing out the potential for improvement in order to achieve a significant productivity increase and promote ergonomics at the same time. Adopting a learning-by-doing approach allows you to design low-waste, flexible assembly processes. At the our BestPractice partners' plants, you will experience what one-pieceflow, Kanban and zero defects quality really mean in practice.

HOW? You will familiarize yourself in detail with lean methods and tools, and design lean assembly processes step by step. Practical visualization on the shop floor at the partner facility, as well as direct application of the methods in case studies and in the practical workshop, will have a positive impact on the success of your implementation at your own company. Benefit from mingling with expert colleagues from a wide range of industries and company structures and expand your network.

WHAT? »» The basics of lean management in the context of lean assembly »» Introduction to the value-added system of the BestPractice partner »» Just-in-time simulation, from job-shop manufacturing through to flow production »» Value stream analysis and design, roadmap for the perfect value stream »» Performing a task analysis and potential assessment »» Layout planning and design of assembly workplaces with cardboard engineering »» Visualization, takt diagram, two-hand analysis »» Best Point provision of tool and material »» Plus: Final test to confirm content has been understood

5 DAYS EUR 2890 / CHF 3290 INCL. WEB-BASED TRAINING "LEAN BASICS" BEFORE STARTING TRAINING WEB CODE: www.staufen.ag/DE-175

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STAGE 2

Lean assembly

TRAINING PROGRAMS

LEAN EXPERT AND LEAN TRAINER

Methods for lean assembly (small-scale)

VISI

WHY? Are you facing the challenge of trying to get a large volume of products to flow during assembly? Are client-specific features in your small-scale assembly operations complicating the logistics? In this training course, you will learn about a company going through the lean transformation process. You will understand how the

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FOR WHOM? Aspiring improvement experts, production managers, schedulers, supervisors, team and group leaders, as well as (junior) executives from Production/AV and Lean/CIP

takt time of even large tasks can be balanced and how a model mix sequence can be used to compensate the different work content of variants. Experience how effectively just-in-sequence provision can be with a direct connection between pre-assembly and the client-specific components to the main assembly and how this helps reduce waste.

HOW? You will use the basics of lean processes to perform detailed analyses of real processes to identify waste. On the shop floor at the partner plant, you will design a flow assembly in line with lean principles. This will help you learn about the tools needed to both recognize and bring out optimization potential in your company. Benefit from mingling with expert colleagues from a wide range of industries and company structures and expand your network.

WHAT? »» The basics of lean management in the context of lean assembly »» Simulation: One-piece-flow for ideal lean production and standard work »» Balancing cycle times by basing them on takt time »» Model mix and modularization »» Just-in-sequence connection of the pre-assembly station to main assembly »» Tools and methods for implementing logistics principles and material flows »» Layout planning of assembly workplaces with cardboard engineering »» Visual management as a management tool in production

5 DAYS EUR 2890 / CHF 3290 INCL. WEB-BASED TRAINING "LEAN BASICS" BEFORE STARTING TRAINING

»» Plus: Final test to confirm content has been understood

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STAGE 2

Lean order fulfillment

VISI

WHY? Is your organization already successfully geared towards the value stream? Excellent processes are created by eliminating and avoiding waste, as well as focusing the highest concentration on "genuine" added value. Lean order fulfillment is a holistic approach to create optimized results when processing client orders and projects. In

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FOR WHOM? Aspiring improvement experts, team leaders, group leaders and project managers, as well as (junior) executives from R&D, Lean/CIP, Sales/ Service, Production/Logistics/AV and administrative departments

LEAN EXPERT AND LEAN TRAINER TRAINING PROGRAMS

Methods for lean order fulfillment

this training session, you will learn about lean principles and methods as a way of reducing processing times and increasing both efficiency and transparency. Clarity and measurability in each processing phase of production specific to client orders can help detect deviations from the target state early and introduce counter-measures.

HOW? As part of a simulation, you will design a new, optimized processing procedure stepby-step. The training session's intense focus on practical elements guarantees that you will gain directly implementable ideas for your own lean and sequenced organization. Use Shop Floor Managementto lay the foundations for continuous further development of your processes. Mingling with expert colleagues from a wide range of industries and company structures will also allow you to gain valuable inspiration for your day-to-day work.

WHAT? »» The basics of lean management in the context of lean order fulfillment »» Methods and tools to analyze administrative processes »» Simulation: Bringing out optimization potential with value stream analysis and design

5 DAYS

»» Target concept creation for waste-free order fulfillment

EUR 2890 / CHF 3290

»» Stumbling blocks and successes when introducing lean processes

INCL. WEB-BASED TRAINING "LEAN BASICS" BEFORE STARTING TRAINING

»» Development and establishment of a multi-project management info board »» Establishment of regular communication across all specialist departments involved »» Conceptual design and implementation of your own communication architecture »» Plus: Final test to confirm content has been understood << CONTENTS

WEB CODE: www.staufen.ag/DE-183

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STAGE 2

Lean administration

TRAINING PROGRAMS

LEAN EXPERT AND LEAN TRAINER

Methods for lean indirect departments

VISI

WHY? Are you aware of the preconception that optimization potential can often only be brought out in production departments? This training will prove the opposite and increase your awareness as to how you can also tap considerable potential in indirect departments. In a step-by-step approach, you will learn where you can generate

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FOR WHOM? Aspiring improvement experts, team leaders, group leaders and project managers, as well as (junior) executives from Purchasing, Lean/CIP, R&D, Sales/Service and administrative departments

the greatest leverage of potential to significantly reduce both waste and processing times. You will use the tools and methods required practically and successfully to increase both efficiency and quality. Thanks to targeted deviation management with KPIs and a consistent order management system, process optimizations are secured in the long term.

HOW? Theory, lean office simulations and practical examples are all used to teach you about effective tools to analyze and optimize your organization at the workplace, process and departmental level. The focus is on your methodological expertise.

Using a roadmap that you create yourself, you will start work on getting your concrete project plan up and running straight away upon returning to your company.

When mingling with expert colleagues from a wide range of industries and company structures, it is important to think outside of your own box.

WHAT? »» The basics of lean management in the context of indirect departments »» Lean office simulation for lean order fulfillment »» Organization of CIP projects in indirect/administrative departments »» Methods for analyzing indirect/administrative processes, such as SIPOC, value stream analysis, swimming lane and others »» Process optimization with EMIPS and value stream design »» Methods for analyzing functions, departments or teams and identifying ­necessary activities

5 DAYS EUR 2890 / CHF 3290 INCL. WEB-BASED TRAINING "LEAN BASICS" BEFORE STARTING TRAINING

»» 5 S in the office »» The basics of Shop Floor Management in the context of lean administration »» Plus: Final test to confirm content has been understood

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WEB CODE: www.staufen.ag/DE-188

STAGE 2

Lean purchasing

VISI

WHY? Are you aware that a lean purchase is a key pillar for your future competitiveness?

Lean purchasing sustainably increases your purchasing performance. Beside the classic objective of cost-optimized material provision, the focus here is on avoiding waste and reducing project processing times. Collaborative supplier integration is a

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FOR WHOM? Aspiring improvement experts, team leaders, group leaders and project managers, as well as (junior) executives from Purchasing, Lean/CIP, R&D, Sales/Service and administrative departments

LEAN EXPERT AND LEAN TRAINER TRAINING PROGRAMS

Methods for lean purchasing

key component in this regard. This reduces the total costs and secures the required quality and on-time delivery at the same time. In this training course, you will learn about both the features and the levers of a lean value-added community to design these profitably and without errors.

HOW? On the basis of demand and procurement market information from illustrative material groups, you will develop purchasing strategies and implementation plans for the low-waste value stream. Besides theory, methods and tools, great emphasis is placed on practical application. Simulations and exercises will provide you with the groundwork for you to apply what you have learned at your own company as a way of optimizing the value stream together with your cross-departmental c­ olleagues and suppliers.

WHAT? »» The basics of lean management in the context of lean purchasing »» Early integration of purchasing processes into development »» Value added in procurement logistics (source), production (make) and ­distribution logistics (deliver) »» Design typical purchasing processes based on the "level concept"

5 DAYS

»» Establishment and implementation of a supplier management system

EUR 2890

»» The basics of Shop Floor Management in the context of lean purchasing

INCL. WEB-BASED TRAINING "LEAN BASICS" BEFORE STARTING TRAINING

»» Promoting staff expertise through knowledge management, performance ­management and skills management »» Necessary activities to improve quality, costs and delivery performance »» Plus: Final test to confirm content has been understood

WEB CODE: www.staufen.ag/DE-193 << CONTENTS

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STAGE 2

Lean logistics

TRAINING PROGRAMS

LEAN EXPERT AND LEAN TRAINER

Methods for lean logistics

VISI

WHY? Day-to-day life at production plants is often characterized by high inventory levels, missing parts and client supply backlogs. Are you also familiar with these problems?

The approach of "separation of value added and logistics" drastically changed the classic material industry. The successful application of lean methods in logistics sup-

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FOR WHOM? Aspiring improvement experts, production managers, schedulers, supervisors, team leaders, group leaders, (junior) executives from Purchasing, Lean/CIP, Logistics and Supply Chain

ports the production at the location required, through BestPoint delivery within the system. Create optimal production logistics by applying short-cyclic material supplies in takt time and introducing "tugger trains". Design the planning and control processes with continuous pull principle from client order, through production, to the supplier.

HOW? This training is characterized by the practice-oriented acquisition of lean tools and methods through simulations and a practical workshop in the Logistics department at the BMW plant in Landshut or Dingolfing. Based on the optimization of a real logistics process, you will achieve 100% supply reliability with minimal inventories.

You will successfully design the change process from push to pull principle. You will learn how to dimension and set up a Kanban cycle and design a tugger train.

WHAT? »» The basics of lean management in the context of lean logistics »» Differentiating between consumption-based and requirements-based control »» The advantages and disadvantages of an in-house or external milk run »» Calculating a Kanban circuit »» Approach to logistics problems in line with lean principles, targeted development of solution approaches »» "Beer" distribution simulation: Logistics planning and control, as well as order fulfillment

5 DAYS EUR 2890 INCL. WEB-BASED TRAINING "LEAN BASICS" BEFORE STARTING TRAINING

»» Leveling and smoothing fluctuations in multi-stage supply chains »» Plus: Final test to confirm content has been understood

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STAGE 2

Lean construction

VISI

WHY? Are you looking to expose any waste and buffers in your construction site processes?

Lean construction refers to the holistic approach for achieving measurably sustainable results when executing construction projects by eliminating and avoiding waste, as well as a very keen focus on value added. In this training session, you will learn about the kind of lean principles and methods that are used worldwide, including in other industries, to tap potential on construction sites. With transparency and

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FOR WHOM? Aspiring improvement experts, project managers, construction managers, civil engineers, supervisors, burnishers, work planners, process optimizers and (junior) executives that work with improvement activities in construction processes

LEAN EXPERT AND LEAN TRAINER TRAINING PROGRAMS

Methods for lean construction

measurability in each phase of execution, you will use resources in a t­ argeted way and avoid waste.

HOW? Learn about introducing lean management to construction sites. Based on a simulation, you will experience the real-world relevance of the approach and create your own personal implementation plan. Recognize key benefits of a collaborative cycle planning method and engage in goal-oriented communication with the right KPIs. Communicate in real time between the construction site and your office, solve problems, employ deviation management and establish complete transparency regarding the progress of construction work.

WHAT? »» The basics of lean management in the context of lean construction site ­processes »» Value stream and task analysis to uncover optimization potential »» Cycle planning according to the just-in-time principle and one-piece-flow »» Cooperative planning methods (e.g. Last Planner®, cycle control with sequences of trades, Kanban) »» Improved control thanks to on-site management and regular communication »» Structured problem-solving methods

5 DAYS EUR 2890 INCL. WEB-BASED TRAINING "LEAN BASICS" BEFORE STARTING TRAINING

»» Areas of application, methods and benefits of BIM and digitalization »» Plus: Final test to confirm content has been understood

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STAGE 3

Top-up training to become a lean trainer

TRAINING PROGRAMS

LEAN EXPERT AND LEAN TRAINER

Teaching and organizational skills

VISI

WHY? Change requires reserves! After all, only those who still have reserves are capable of change. Are you looking to establish a professional internal organization for your improvement process? One of the key duties of the head of the CIP office is to continuously extend the knowledge and skills of trainers in line with the "Train-the-Trainer"

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FOR WHOM? (Aspiring) heads of improvement management who can already demonstrate successful project documentation and have successfully completed stages 1 + 2

principle. The CIP office head has cross-functional expertise, is a sparring partner for management and employees alike and holds specialist responsibility for lean-compliant further development of the company. These duties require a profound understanding of lean management and BestPractice structures across all departments, as well as the willingness to assume leadership.

HOW? Through business games and theory units, you will develop your expertise in conveying lean methods and tools for your daily work as a trainer. You will spend 1.5 days working on real-world processes in a team as part of a practical workshop on the our practical partner's shop floor. You will work in a targeted way on your trainer skills and strategically expand your lean network. Continue to benefit from cross-sector expert contacts, even after completing this final training session.

WHAT? »» Expanding specialist and methodological expertise »» Necessary activities at the CIP office as part of the lean transformation »» Moderating the just-in-time simulation »» Motivation theories, social and leadership skills and how to handle conflict »» Effectively conveying lean knowledge, as well as analysis methods and techniques

PREREQUISITES You have been holding CIP workshops for some time and confidently apply basic lean methods in your field.

»» Resolving a real problem in the practical workshop (1.5 days) at one of our ­BestPractice partners, including final presentation to the management team »» Reflection on your own role as head of CIP office and the framework required for this

5 DAYS EUR 2790 / CHF 3240

»» Plus: Final test to confirm content has been understood

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Registration Training selection

Contact details of participant

Title 1

First and last name

Date

Company

Title 2

Position

Date

Address

Title 3

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Date

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Different invoicing address First and last name Company Address ZIP code, city Country

PLEASE SEND US YOUR REGISTRATION AS FOLLOWS:

REGISTRATION CONDITIONS:

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The participation fee is plus VAT and should be paid within

DE: m.messerle@staufen.ag

14 days after receiving the invoice. The fee includes documen-

CH: akademie_anfrage@staufen-inova.ch

tation, lunch and drinks. Once we have received your registration, you will receive a booking confirmation, including

By fax:

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DE: +49 (0) 7024 8056 111

ticipants for reasons of competition and to change the time/

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location of the event. Participants may cancel free-of-charge up to 14Â days prior to the event. Any cancellations made after

or you can use our online registration option:

this time will be invoiced in full. However, you are of course

Simply select your seminar at www.staufen.ag/seminare and

welcome to nominate a substitute participant if someone is

use the convenient online registration form.

unable to attend.

Our standard terms and conditions apply to the registration conditions (www.staufen.ag/agb).

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