Introduction to Lean for Bespoke Manufacturing
Bespoke manufacturing is a challenging and highly competitive sector, and it has never been more important to understand how the fundamentals of lean manufacturing apply to this type of business. When properly understood and applied, lean thinking has the power to significantly boost productivity, quality and profitability by increasing throughput and reducing defects. This engaging, interactive and highly practical workshop provides the participants with a fundamental knowledge of lean concepts and how to apply them in a practical way within a bespoke manufacturing environment.
As with all our training workshops, the content is tailored to suit the context of your business and is facilitated by a trainer with significant experience in applying lean within small to medium bespoke manufacturing enterprises. Theory sessions alternate with practical exercises and simulations throughout the workshop to help develop the concepts using a variety of learning styles and to demonstrate the practical application of the theory.
The simulation exercise included in the two-day version of the program, involves participants conducting a manufacturing process, measuring their output and quality. This is a key part of the workshop, helping to make the theory real. It shows just how much benefit can be realised from just a few simple changes in approach and creates buy-in and enthusiasm for change amongst your team. At the conclusion of the workshop, participants have a framework that they can apply to get real results, especially when supported by ongoing coaching from our highly experienced lean practitioners as your team embeds the learning in the real world.
About our training
Please listen to Mr Chris Baker discuss why Kallista Consulting training workshops get results
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High Waste Levels
Without a lean culture, organisations often overlook excessive waste in processes, including wasted time, materials, and labour. This inefficiency leads to higher operational costs and less competitive pricing, reducing the overall profitability and sustainability of the business.
Inflexibility and Slow Adaptation
A non-lean culture typically resists change, making it difficult for organisations to adapt to market changes or innovations swiftly. This rigidity can result in missed opportunities and an inability to respond effectively to customer demands or technological advancements.
Poor Employee Engagement and Morale
Lean culture emphasises continuous improvement and employee involvement in problem-solving. Lacking this culture can lead to low employee engagement, as workers may feel their ideas are undervalued. This lack of involvement can diminish morale, reduce productivity, and increase turnover rates.
Workshop Agenda
This program has been specifically designed for employees working within a manufacturing environment, and is for you if:
You are a manager or team member working as part of a manufacturing team where you are accountable for completing manufacturing work on time to a certain quality.
You are part of a team supporting manufacturing activities, including:
Inventory management, warehousing and procurement
Engineering design and drafting
Planning and Scheduling
Management of ERP/MRP systems
Module 1: Lean Fundamentals
Overview and origins of Lean
The Goal: What all organisations are trying to achieve
The 5 Lean Principles
Value Added Work vs Waste
The 7 Wastes of Operations
The Workcell Rectangle
Exercise (2-day Version Only)
Part 1 of a simulation exercise using a bespoke manufacturing process to highlight the typical problems that exist and the impact they have on productivity
Module 2: A Model for the Lean Business
Lean Foundations
Visualisation of Purpose
5S Overview
Process & Value Stream Mapping
Lean Pillars
Standardisation
SOPS
Standardising the Non-Standard
Flexibility & Skills Management
Workflow and Pull Systems
Batch vs One Piece Flow
Kanban, Supermarkets & Water Spiders
The Pursuit of Perfect Quality
Daily Lean Management
Exercise (2-day version only)
The simulation exercise continues, layering in changes to show how they enhance productivity
Module 3: A Framework for Business Transformation
Kaizen
Prioritising projects
Using DMAIC to plan projects
A3 reporting
How to get the most out of your improvement projects
Exercise (2-day version only)
The simulation exercise concludes, showing a major improvement in throughput and quality.
Key Learning Outcomes
Having completed this course, participants will understand:
How to focus their thinking when examining a process by observing delivery and quality
The concept of Waste versus Value Adding Work
The 5 principles of a lean organisation
The Workcell Rectangle - How the lean principles apply to a workcell
The core elements of a model for a lean organisation
How to create an ordered and structured workplace using the principles of 5S
How to map processes using Value Stream Mapping and why that is important
The importance of quality and how to continuously improve
The Theory of Constraints
How to schedule bespoke work
How to run or participate in a kaizen event
How to run daily toolbox meetings using visual boards
Why our clients love our training:
high quality training workshops designed to be practical, with learning that can be directly applied within the workplace
workshops can be tailored to your sector and specific requirements
facilitated by industry experts
quality course materials; printed in colour on high gsm paper
Kallista Consulting’s network of highly experienced industry professionals develops all of our workshops. They are experienced facilitators with engaging styles who easily command credibility with their audiences.
By incorporating engaging exercise across the duration of each workshop, participants are able to practice the techniques, enabling them to translate the training directly into their workplace to deliver practical outcomes. The materials provided to each participant are comprehensive guides in themselves and include opportunities for participants to record notes and action plans.
Every course can be delivered on-site, remotely via teleconference or through online training platforms and can be customised to provide context within your specific industry and tailored to your desired learning outcomes.
What People Are Saying
“I love the flexibility in the approach that Kallista Consulting takes to tailor a program to meet our specific business challenges. In addition, the energy and personal commitment the team takes to deliver the best-in-class learning experience”
Bobby Pavlickovski
Director Operations | Thales Australia
“Having worked with Kallista Consulting for more than 10-years now, Entegra have found Chris an excellent resource to align with for implementing process performance, systems & structure, driving a culture of continuous improvement and developing emerging leaders amongst our organisation.”
Laurie McCalman
Managing Director | Entegra Signature Structures
Who we work with
Manufacturing
Government
Police & Defence
IT & Software
Education
Logistics
& FMCG
Utilities
& Recycling
Project Management
“We were introduced to Chris by a trusted colleague. Chris is a highly knowledgeable consultant who was able to execute needed change in our business at a challenging time. Besides Chris’s knowledge and experience, his greatest attribute was his ability to engage with our team at all levels. He took the time to connect with every member of our team. It was this understanding that built a trust in our team that was the driver for success. I can not recommend Chris highly enough!”
Catherine Hargreaves
General Manager | Hargreaves Joinery
Want to learn more or discuss the course?
We can tailor our workshops to suit your requirements, so if you want the best possible training for your team, why not simply book a time to talk directly with our Customer Service Professional to talk about your specific training needs.
For a detailed overview and agenda of this workshop, download the Customer Service Training Brochure
Client Partnerships
