Lean Thinking has become one of the leading mechanisms to bring about change and significantly improve capability in any organisation.

Lean Thinking applies equally to any type and size of business, as the principles focus on the practices used within the business to translate customer demand through to fulfilment. These principles work in harmony with the technical elements of the business and have proven to bring significant financial and cultural gains.

Simply Lean teaches these Principles and Tools in Workshop and/or On-Job-Training situations tailored to the organisation, providing the Team with the knowledge and skills to implement Lean Thinking Principles throughout the entire business.

Building strong relationships we partner and mentor the Team on their Lean Journey developing skills, knowledge and engagement, creating a culture of continuous improvement throughout the business.

We undertake a Business Analysis to understand the challenges the business is facing and develop a Lean Implementation Plan, in association with the Leadership Team, to resolve these challenges using Lean Thinking Principles.

We teach all aspects of Lean and their unique application to your business including Value Stream Mapping, 5S, Kanban, Heijunka (Load Levelling), Jidoka (Error Proofing), Problem Solving, Flow (including Single Piece Flow), Standardisation, Communication, Process Development, TPM, Measurement and Management Reporting, Change Management.

The skills and knowledge developed by individuals allow them to qualify for the National Certificate in Competitive Manufacturing.

Our Team is highly skilled and experienced with more than 25 years working in Lean environments and teaching and implementing Lean Thinking in more than 80 organisations from very diverse business sectors.

Costs are $1900 + GST per day per consultant for the organisation. less

Today’s business environment demands that organisations continually challenge the problems that inhibit their ability to achieve their strategic and operational goals.

These challenges manifest themselves through a variety of symptoms such as:

• Customer demand beyond current capability
• Delivery dates slipping
• High warranty costs
• Unreliable machines and equipment
• Too many material stock-outs
• Reduced profitability and pressure on price
• Cash-flow issues – high levels of working capital
• Too much reliance on ‘the boss’ to make things happen
• Working long hours and still rushing on Fridays to ‘get things done’
• Limited space to do the work – no space to grow the business
• High work in progress - possibly cluttered and untidy
• Increasing number of HR and H&S issues
• High staff turnover – difficulties in finding good staff
• Staff walking about – searching for things, clarifying requirements, moving work
• People or machines waiting on materials or information

For organisations to improve profitability and remain competitive, these issues must be resolved. If the list struck a few chords, you need to tackle these strategically in order to sustain the improvements – ‘fire fighting’ is not the solution.

The workshop will provide an insight into solutions to these issues and the structure to maintain and grow the level of improvement you need to remain competitive and profitable.

Applying these solutions will enable you to:

• Reduce process costs
• Reduce cap-ex, overhead and inventory costs
• Improve workflow and processing capability
• Increase process agility and response to customer demand
• Enable you to meet increasing customer demand and grow the business
• Improve quality and grow your customer base
• Develop your teams’ and your leaders’ knowledge and skills
• Improve H&S throughout the organisation
• Improve staff engagement, morale and retention

This one-day Productivity and Improvement Workshop will provide participants with the opportunity to rethink how their organisation’s current processes and functions impact on quality, delivery, cost and safety. They will also learn how Lean Thinking practices can deliver the sustainable results to achieve the goals they and the organisation are seeking.
In this hands-on business simulation workshop participants will:

• Learn how to identify value and waste in their organisation using tools such as Value Stream Mapping
• Understand how the five key principles of Lean Thinking will benefit their organisation
• Understand how Just-in-Time principles can be employed to improve productivity
• Understand the importance of the roles that culture and people play in an organisation
• Understand the principles of 5S and how to use them to create a safe, visually controlled and more productive environment
• Quantify wasteful elements within the business simulation and relate these directly to their own organisations.

This workshop is aimed at business owners, managers and supervisors confronting the issues noted above — particularly in response to increasing capacity while being constrained by available resources. They will also have influence within their organisation to potentially change the pathway for the future development of their business practices.

Pricing for this one day workshop is $495 +GST per person.

Tailored costs for organisations are available so please contact us to discuss. less

"Teaching the Lean Tools associated with 5S in a Workshop and On-Job- Training situation.

Introduction to Lean Thinking and teaching both 5S Elements (Sort, Set-in-Order, Sweep & Shine, Standardise, Sustain) and their application. Understanding Waste in Lean terms and its relationship with 5S.

Undertaking a “Waste Walk” during a workplace observation. Hands-on application of the 5S elements.

Teaching how to undertake a 5S Self Audit and developing an associated Improvement Plan.

Delivered by members of our Team with skills from working in Lean environments including Toyota, Rolls Royce and Electrolux. Our Team have a wide range of skills and experience implementing Lean Thinking in more than 70 organisations from very diverse business sectors.

1 Day
This is conducted as an in-house workshop for each client.

Our pricing is based on a rate of $1800 + GST per day per Coach for the organisation. Initial start-up materials of approximately $200 + GST .

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Introduction:
A prevalent impact on productivity is the lost time owing to poor workplace organisation and resultant inability to find tools, materials and information, or even enough space to undertake daily work activities. 5S is a tool that helps people create highly organised and efficient workspaces and environments and help change behaviours to maintain and improve these.

The topics to be covered are:
• The philosophy behind workplace arrangement and 5S as a driver for improvement
• A practical insight into the impact of poor practices
• The tools of 5S and how to apply them

Outcomes:
In this workshop participants will:
• Learn why workplace arrangement is important from both safety and organisational aspects
• Understand how to bring structure to improving workspaces
• Understand the principles of 5S and how to use them to create a safe, visually controlled and more productive environment

Who should attend:
This workshop is aimed at business owners, managers and supervisors wishing to begin their Lean activities with a tool that everyone can be involved in. Particularly relevant to those who have completed our Introductory Module – Productivity and Performance Improvement Workshop.

Cost:
Pricing for this half day workshop is $275 +GST per person less

Introduction:
Early problem identification is one of the biggest issues facing organisations as too often a problem is not noticed until too late. If we were able to see a problem coming well before it becomes a catastrophe, appropriate actions can be taken to minimise or even avoid it. If we visually understand our process performance we have a greater chance of averting these catastrophes and improve. Ultimately prevention is the best outcome but first we have to see and understand our problems.

The topics to be covered are:
• What are visual controls
• Understand visual controls as a method to identify problems
• The importance of Measurement to understand real-time performance
• Visualising problems through measurement

Outcomes:
In this workshop participants will:
• Learn why measurement at the process level is an important influence on success
• Understand the different types and applications of visual controls
• Understand how to use visual controls in the continuous improvement arena

Who should attend:
This workshop is aimed at business owners, managers and supervisors wishing to advanced their understanding of Lean Thinking. Particularly relevant to those who have completed the Introductory Module – Productivity and Performance Improvement Workshop.

Cost:
Pricing for this half day workshop is $275 +GST per person. less

Introduction:
Organisations are often faced with making significant changes within their business and this can be a challenging task. This workshop will help participants understand the key points in managing and bringing about positive change in a business environment. Kotter’s approach is used as it is widely recognised as the essential process for effective and successful organisational transformation. Participants will also be introduced to effective governance of their Lean Programme to bring structure and control to managing the programme to ensure success.

The topics to be covered are:
• Understanding the impact of change on people in the midst of organisational change
• Kotter's 8 steps to successful transformation
• Governance structure and programme management in a Lean Organisation

Outcomes:
In this workshop participants will:
• Understand how to create an environment of positive change
• Learn how to apply the right approach to keep people engaged
• Understand the importance of effective governance of their Lean Programme
• The makeup and selection of the governance team
• How to structure the management of the Lean programme


Who should attend:
This workshop is aimed at CEO’s, business owners, managers and supervisors wishing to understand more about the right steps to take when changing the makeup and practices of the organisation.

Cost:
Pricing for this half day workshop is $275 +GST per person. less

Introduction:
Lean Leadership is different to traditional leadership and your Lean Journey will suffer without the behaviours and practices of strong and active Lean Leadership. This workshop brings clarity to these behaviours and practices and how they make a positive difference to Continuous Improvement activities throughout the organisation. Lean Leaders are at the core of an organisation wanting to develop their improvement capability and foster growth in people and processes.

The topics to be covered are:
• Management and Leadership
• Behavioural differences
• The mind-set of a Lean Leader
• Teaching methods of a Lean Leader
• The 5 Lean Leadership Actions

Outcomes:
In this workshop participants will:
• Understand the differences between management and leadership
• Understand the behaviours of a Lean Leader
• Learn new teaching methods to help grow their team
• Understand the 5 Leadership Actions to foster a strong culture of Continuous Improvement and organisational growth

Who should attend:
This workshop is aimed at CEO’s, business owners, managers and supervisors wishing to learn the characteristics and behaviours of a Lean Leader.

Cost:
Pricing for this half day workshop is $275 +GST per person. less

Introduction:
Leader Standardised Work is a key part of a Lean Leaders daily management activities. It effectively brings structure to these activities and provides for an environment where responsibility and accountability are fundamental to the success of a Lean Programme. Practicing Leader Standardised Work brings clarity and understanding to what is happening in the processes the leader is responsible for and brings structure and purpose to their Gemba Walks.

The topics to be covered are:
• The philosophy behind structured activities for leaders
• A practical insight into how to create Leader Standard Work
• The importance and use of Visual Controls
• How to undertake an effective Gemba Walk
• How to use your Gemba Walk as a teaching opportunity

Outcomes:
In this workshop participants will:
• Build their knowledge about bringing structure and accountability to their day
• Create a Leader Standardised Work example
• Learn how to use Visual Controls during a Gemba Walk to understand the current condition
• Learn the language and behaviours of Leaders undertaking Gemba Walks.

Who should attend:
This workshop is aimed at CEO’s, business owners, managers and supervisors wishing to advance their Gemba Walking skills.

Cost:
Pricing for this hlaf day workshop is $275 +GST per person. less

Introduction:
Join us in this remarkable opportunity to learn from a Japanese Toyota factory Manager, Sensei and Kaizen Leader.

Akinori Hyodo from Toyota’s HiAce manufacturing plant in Japan will lead a two day Masterclass in Lean Thinking.

The Masterclass provides the foundations of Lean Thinking including insights and examples used directly within Toyota, including an overview of the operations at the Toyota HiAce Factory in Japan, as well as an afternoon tour and mini diagnosis at a local company. Hyodo Sensei explains Lean in a way that is profoundly easy to understand and simplifies the approach to Lean Thinking and Continuous Improvement across industry.

Hyodo Sensei is a long-time Toyota Production System Leader, former Factory Manager and Kaizen Leader. Having retired as a Factory Manager, he now heads the Kaizen Training arm of that same Toyota factory providing Lean training courses for companies in Toyota’s supply chain.

• Factory Manager Toyota Parts Factory
• Factory Manager at Toyota Assembly Plant
• 13 year member and leader of All-Toyota Kaizen Promotion Team
• 27 years leading TPS Development within the No.1 ranked Toyota factory for Quality
• Consults globally with wide range of non-automotive companies

Topics:

Day 1:
• TPS Foundation Principles
• Developing human assets
• Role of top management
• Factory visit and diagnosis

Day 2:
• Factory visit review
• 5S and Visual Management
• Standardized Work creation
• Continuous Improvement Culture


Target Audience:
This Masterclass has been developed for Managing Directors, Managers and Leaders in Operations, Production, Continuous Improvement, or Quality interested in fostering a culture of Continuous Improvement within their organisation. Learn first-hand how process improvement is achieved within Japan’s leading companies, and more importantly, how to begin to implement or advance these practices within your organisation.

Particularly relevant sectors include Manufacturing, Food and Beverage and Service.

Eligibility and Registration of Interest:
To register your interest in this event visit Simply Lean Events and complete the Registration Form.
Spaces are limited and Simply Lean Business Solutions Limited, and the local host company reserve the right to decline registrations owing to conflicts of interest. Confirmation of your Registration will be by return email.

Cost:
Pricing for the two-day Masterclass:
Standard Fee $1295 + GST per person
Earlybird Fee $1145 + GST per person (for Confirmed Registrations six weeks prior to the Masterclass) less

Developing problem solving skills is an essential element in advancing as organisation and reducing costs. Often these skills are missing and problems continue to surface – many repetitively. This is because the actual Root Cause has not been found and therefore the countermeasures or fixes for the problem will only be effective temporarily.
True Root Cause Analysis needs to be undertaken to ensure problems are resolved once and for all. This Structured Problem Solving workshop brings clarity to the actual process of going about problem solving as well as introducing participants to the key analysis tools that help define the Root Cause.

The topics to be covered are:
• Problem identification
• Plan, Do Check Act problem solving process
• Analysis tools for data collection and validation

Outcomes: In this workshop participants will:
• Understand how to effectively use the PDCA cycle
• Why finding the Root Cause is so important
• Understand how to use tools to focus action on the Root Cause
• Understand how to validate the effectiveness of the resolution to the problem


Facilitator: Tony Burns began work as a trainee engineer with Rolls-Royce plc in Derby, UK. Over the next 20 years, he qualified as a management accountant, became an accredited Lean/6-Sigma business improvement leader as well as an accredited business performance coach through the Oxford School of Coaching and Mentoring. Tony has worked for Simply Lean Business Solutions since 2009 in diverse business sectors.

Who should attend: This workshop is aimed at Managers, Supervisors and Team Members wishing to learn how to effectively solve problems so they don't recur.

Cost: Pricing for this half day workshop is $275 +GST per person. less

Day 1: Productivity and Performance Improvement
Day 2: Leadership Module 1: Leading Change and Programme Management
Day 3: Leadership Module 2: Developing Continuous Improvement Leaders
Day 4: Leadership Module 3: Leader Standardised Work and Gemba Walks

For details on each of these workshops please select the individual modules listed elsewhere on this site.

Bonus:
Participants of the full course are offered a free 1 hour coaching/mentoring follow-up visit 2-3 weeks following each Module.
Participants of the full course also receive a 10% discount.

Cost: Pricing for the full course is $1371.38 less

We meet many organisations who have begun their Continuous Improvement Programme in earnest only to find the demands this puts on the business, sees the Programme either plateau or slip back despite the efforts of the Team. Organisations need to take stock of where they are on their Journey and begin taking the right steps to re-establish and advance their programme in a manageable way.

Our Rethinking Lean Programme gives you the opportunity to revitalise your programme, refresh your team’s understanding and application, recover lost ground, or advance into new territory.
The programme is completely customizable to suit your level of knowledge and understanding and meet your specific needs.

An initial conference call with us defines these needs and collectively we agree on the training and applications that you need to meet your goals and ensure this fits within your budget. Coaching is undertaken as a mix of Classroom and/or On-Job-Training environments tailored to your organisation and culture.

Our Team is highly skilled and experienced with more than 25 years working in Continuous Improvement environments; teaching and implementing in more than 100 organisations from very diverse business sectors.

Pricing is $1800 + GST per consulting day therefore total cost is dependent on the number and duration of the Modules selected.

Rethinking Lean Programme:
1. Initial Assessment - Online conference call to discuss current status of Lean knowledge and application, and to understand the objectives the client seeks.

2. Module Selection - Module selection is taken from the categories below which then provides the client with a customized Training and Application Development Programme.

3. Modules

Core Application Competencies
1. Continuous Improvement Philosophy
2. Value and Waste
3. Daily Team Meetings
4. 5S Workplace Arrangement and Housekeeping
5. Measurement
6. Visual Controls
7. Continuous Improvement Process

Leadership Competencies
1. Programme Governance
2. Change Management
3. Developing Lean Leaders
4. Leader Standardized Work
5. Gemba Coaching

Advanced Application Competencies
1. Value Stream Mapping
2. Just-in-Time and Kanban
3. Structured Problem Solving (PDCA)
4. Total Productive Maintenance (TPM)
5. Changeover Reduction (SMED)
6. Load Leveling (Heijunka)
7. Error Proofing (Jidoka) less