A3 Problem Solving Session Including Simulation

This is everything your Lean Facilitator needs to teach an effective A3 Problem Solving class for your associates. The session is designed
for 4.5 hours of classroom time learning the problem solving tools and how to use the A3 template, followed by the 3.5 hour team-based
simulation.

Problem Solving tools include:

- Root Cause Analysis
- Process Flow Charting
- Value Stream Mapping
- Pareto Chart
- Fishbone Diagram
- Histogram
- Scatter Diagram
- Control Charts & Process Capability
- Error Proofing

This simulation kit provides an opportunity for the participants to actually use the 8 steps of the A3 Process and fill out the included A3 form. The kit is designed for up to three teams (six associates per team). The simulation gives the team a chance to demonstrate their A3 Problem Solving knowledge in a simulated, yet "business-like" environment, and confirms their understanding of these techniques through the use of team "report-out" activities. The A3 steps are:

1. Identify the Problem or Need
2. Understanding the Current Situation/State
3. Goal Statement--Develop the Target State
4. Root Cause Analysis
5. Brainstorm/Determine Countermeasures
6. Countermeasures Implementation Plan
7. Check Results--Confirmation of Effect
8. Update Standard Work

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Kit Includes:

- 112 PowerPoint slides on a site license CD
- A3 Problem Solving simulation using our standard wood trucks
- A3 template--blank and on CD
- A3 template--filled in per the steps in the PowerPoint slides and    on CD
- 18 laminated problem situation and statement forms
- Implementing World Class Manufacturing book as a reference for the problem solving tools

- Set of Poker Chips for a problem solving exercise

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Item #11259
$420.00

5S Session Including

Videos and Simulation

5S is a powerful Lean tool that when implemented will improve safety, housekeeping, and organiza-tion. 5S reduces business waste by eliminating searching, hunting, or looking for anything in the administrative area, office, or the factory.

This is everything your Lean Facilitator needs to teach a powerful introduction to 5S session for all of your associates. This session is designed for 6 hours of classroom time (including two videos), followed by the 2 hour 5S simulation. This simulation includes a 5S audit exercise.

Course Content includes:

• 5S -- paving the approach
• Where does 5S apply
• How 5S improves the workplace
• Origin of the 5S's
• Definition and application of: Sort, Straighten/Set In Order, Sweep/Shine, Schedule/Standardize, Sustain
• Visual controls and production boards
• 5S and visual controls in the office A 5S simulation

Upon completion of the 5S Visual Enterprise session, participants will be able to:

• Define the 5S's
• Use Red Tags to identify unneeded items in their workplaces
• Apply 5S techniques to layout a work area
• Use visual techniques to speed the flow of information and material
• Link 5S activities to bottom line measurements
  

Kit includes:

• 112 PowerPoint slides on a site license CD
• DVD -- 5S Factory Makeover (Society of Manufacturing Engineers)
• DVD -- Introduction to Visual Controls (Society of Manufacturing Engineers)
• 5S Simulation as described in the PowerPoint slides
• 5S audit and scoring sheets -- blank and on the CD
• Book -- Implementing World Class Manufacturing as a reference for the 5S PowerPoint slides

Available without the 5S Videos for $541.00

Item #11260
$904.00

5S Session and Simulation Only     

(No Videos)

Item 11268

$541.00

Value Stream Mapping Kit

Contains everything you need to facilitate successful Value Stream Mapping events.  Kit Contains:

Item# 11257

$83.00

5S Event Kit

Contains everything you need to run a successful 5S Kaizen Event!

Kit Contains:

Kaizen Newspaper Flip Chart Pad: Printed on high quality, glossy paper for a professional look, our Kaizen newspaper can be used to visually track Kaizen action items and their status. 25 Sheets, 27" x 34".  (Also available separately, Item #11261, $39.00)

"Kaizen Event" Vests: Our "Kaizen Team" event vests are made of a light weight mesh with a velcro closure. Can be given to participants as a badge of their participation in a Kaizen event. Package of 12.

5S Red Tags (200 Tags plus wires)

TPM Action Tags (100 Tags plus wires)

Item # 12260
$149/Kit

Kaizen Event Kit

Run a more organized and efficient Kaizen event!

Kit Contains:

Kaizen Newspaper Flip Chart Pad: Printed on high quality, glossy paper for a professional look, our Kaizen newspaper can be used to visually track Kaizen action items and their status. 25 Sheets, 27" x 34". (Also available separately, Item #11261, $39.00)

"Kaizen Event" Vests:  Use our "Kaizen Team" event vests to easily identify team members and to let everyone know that something special is taking place. Vests are made of a light weight mesh with a velcro closure. Can be given to participants as a badge of their participation in a Kaizen event. Package of 12.

Item # 12259

$99.00

Kit contains everything you need to start your journey to becoming world class! Save 23% off the retail price when ordered as a kit.

Kit contains:

(2)   5S Red Tags (Pkg of 100, plus wires)
(1)   Putting 5S to Work Book
(1)   5S Pocket Cards (Package of 25)
(2)   2" Yellow/Black Safety Tape
(1)   TPM Yellow Tags (Pkg of 100, plus wires)
(1)   Implementing World Class Manufacturing Book
(1)   Kaizen Vests (Pkg/12)
(1)   5S Red Tag Parking Lot PVC Sign

FREE! World Class Manufacturing Hat (while supplies last)

Item #11256

$197/Kit

Lean Office Simulation

Eric Matthias, Menasha Packaging Company

Ted Angelo, Grunau Construction Company

Item # 11280

$245.00

Error Proofing & Problem Solving Simulation

Kit includes simulations for both Error Proofing and Problem Solving. The kit is designed for up to three teams (six associates per team) who have been trained in Problem Solving Tools, and should be facilitated by an experienced Team & Problem Solving Trainer. The Simulation Kit gives the team a chance to use their Problem Solving Tools and Error Proofing techniques in a simulated, yet "business-like" environment, and confirms their understanding of these techniques through the use of team "report-out" activities.

Problem Solving:

This simulation kit provides an opportunity to actually use the following tools:

- Problem Definition
- Fishbone Diagram and Multi-voting
- 5 Whys
- Brainstorming
- Developing an Action Plan

This exercise takes approximately 3 hours to complete.

Error Proofing :

After teams have been trained in Problem Solving, this Error Proofing Simulation is to be used as part of an Error/Mistake Proofing class. This exercise teaches the team how to apply the following Error Proofing techniques:

- Design for Manufacturing and Assembly (DFMA)
- Detection in Station
- Successive Checking

This exercise takes approximately 1.5 hours to complete.

Item # 11258
$169 / Kit

New! 5S Simulation

Item #12270

$349.00

Push/Pull Simulation (BOX GAME)

                          Kit Components

The Flow Simulation (box game) is an enlightening demonstration of the benefits of one-piece flow pull production and the use of processing cells versus traditional push/batch production. It can be used to compare push versus pull production for either “information product” production in the office or “physical product” production in the factory.

The game compares batch or push production techniques to one-piece pull production using processing cells. It shows how teamwork, 5S, quality, and productivity improve with pull production while reducing WIP inventory, rework, product lead-time and the floor space required. It also illustrates how Setup Reduction and Total Productive Maintenance (TPM) are prerequisites for pull production.

The game requires that you set up a 20'x20' production area with four folding tables (or equivalent) and requires 7 people to run the simulation. The simulation assembles a product (6"x3"x3" Styrofoam box) that can be equated to the office processing of an information product. Three different ways to run production are compared (Push 6, Pull 6, and Pull 1). The game takes about 1.75 hours to complete. Includes an instructional video on DVD.

                                 Actual Simulation

Item #11230

$583 (Instructional DVD Included)