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LEAN Suite

Lean Certification

Whether you’re new to lean or an experienced facilitator, we offer multiple certificate programs. The Lean certification program combines classroom training, simulation and teachback opportunities for participants to hone their problem solving and facilitation skills. Individuals learn the basics of Lean and the various tool applications followed by an introduction to lean culture, lean organizational infrastructure and lean leadership. Participants are assigned an experienced IES “lean mentor” to help guide them in their implementation efforts. Upon the conclusion of the program, participants will select and present a project completed demonstrating the application of the skills and tools acquired through this robust training program. Other available options include a focus on targeted topics such as Managing for Daily Improvement (MDI), Hoshin Kanri (Strategic Planning & Deployment), Toyota Kata and more.

Customized Lean Transformations

Your business is unique, so your Lean transformation should be too. That’s why we customize our solutions, bringing you 5-day overviews, 30-day overhauls and multiple scenarios in between. We are committed to helping affect a sustainable culture change within your organization. To that end, we offer long-term mentoring and follow-up, coaching and further improvement recommendations.

Onsite Offerings Include: Executive Overview Training, Going to Gemba with Purpose, Standard Work for Lean Leaders, Lean Leader Mentoring, Lean Facilitator Training, and Lean Culture Training.

Electronic Lean Office

Organizations that need robust, waste-free, flexible office processes that meet their customer needs and help them survive in the global marketplace turn to us for our Electronic Lean Office solution. We help organizations achieve operational excellence, while providing flexibility in the way processes are managed.

This unique paperless simulation uses an electronic process and “server” to demonstrate the effects of process variation and defects in transactional processes. Process Flow mapping and Lean methodologies are then applied to help alleviate bottlenecks, increase throughput, improve quality and customer satisfaction. Participants will see, through teaching and application, how the lean process works.

Lean for Human Resources

Lean is especially relevant to professionals in the human resources field. We are increasingly being asked to do more with less people. This requires us to do the right things, the right way, with the right people. Getting the “right” people requires us to act faster. How do you reduce time to hire? How do you meet leave of absence requests in a timely and compliant fashion? The Lean process can assist human resources in identifying value, mapping the value stream, creating flow, establishing pull and seeking perfection. We can help you address basic disciplines including Standardized Work, 5S, Error Proofing, Kanban, Visual Control and more.

Lean Service Sector

Our Lean Government rapid implementation process means that you see results instead of endless planning committee meetings. Reveal and correct waste in administrative departments and service delivery processes, so your community enjoys the most value for its dollars. IES has successfully partnered with many local municipalities (small and large) as well as statewide agencies to improve daily work and creatively address common issues using a continuous improvement mindset.

Lean Non-Profit applications help organizations execute rapid cycle improvements to internal processes that have helped increase process efficiency, increase stakeholder involvement and customer satisfaction while decreasing errors, delays and other non-value-added processing steps. Individuals and organizations have made small changes that utilize creativity over capital to brainstorm, test and implement realtime solutions in their places of work.

Lean for the Service Sector applications have
helped organizations primarily focused on customer service, sales and transactional functions improve the way they organize for success. Our lean experts have helped by engaging frontline staff and leadership to focus on where the work is done for opportunities to improve operations. Virtual and traditional Gemba walks can help highlight areas where breakdowns in process, communication, and information sharing might occur. Lean tool applications can then be used to help eliminate variability and standardize interactions with internal and external customers ensuring optimal results.

Lean Healthcare

Lean Healthcare principles streamline processes and seek efficiency to help healthcare organizations achieve results, like decreased wait times and more face-to-face time with providers. Applying these principles may make your patients healthier, your employees happier and your organization more effective. We offer:

  • On-site educational programs and workshops to familiarize you with lean methodologies and tools

  • On-site strategic planning and assessments to help you determine your best path to continuous improvement and lean transformation

  • Customizable, transformation programs to help with your lean journey

  • Facilitation of Kaizen events and value stream maps

  • Lean Leader Coaching and Mentoring (C Suite and Facilitator level)

Lean Manufacturing

The core idea of lean manufacturing is simple—work on identifying and eliminating waste from the manufacturing process. We can help with basic and advanced Lean tool applications including Process Flow and Layout, SMED, TPM, LPD, Value Stream Mapping, 5S, Standardized Work, Error Proofing, Kanban and Visual Management.

Total Productive Maintenance (TPM) is a process that maximizes the productivity of equipment for its entire life cycle to extend the life of the equipment. Through the participation of both operational and maintenance associates, TPM creates an environment that encourages improvement efforts in safety, quality, cost, delivery and creativity. Our program focuses on eight pillars: autonomous maintenance; planned maintenance; early equipment management; quality, health and safety; focused improvement training and education; and TPM in the office. Participants will receive a combination of classroom training paired with realtime instruction and application with an IES expert on the shop floor.

Quick Changeover (SMED): Wasteful, non-value added activity takes place both during machine runtime (external activities) and while the process is shut down (internal activities). SMED workshops focus on reducing and eliminating this waste and increasing capacity,
time availability and resource availability in the process. Changeovers consist of the time between the last good piece off the current run and the first good piece off the next run, at rate.

SMED (Single Minute Exchange of Dies), or Changeover Reduction, focuses on reducing the time and impact of key elements in the changeover process including preparation; after-process adjustment; checking, storing, and moving materials, parts and tools; removing and mounting parts and tools; machine measurements, settings and calibrations; trial runs and adjustments.

Lean Product Development (LPD)

Research shows that companies across the country indicate finding their next new product tops their list of needs and concerns. It might not be easy, but it’s vital to long-term success.

Learn how lean design tools and lean product development can reduce costs, improve resource utilization and accelerate time-to-market for new products and services by eliminating the non-value-added waste in the development stages.

Lean product development can be used by those new to product development or those simply trying to improve their current product or process development.

Learn what waste and value look like in the context of new product development. Learn how to achieve significant improvements in time-to-market, and production costs by applying lean principles to the product development environment.

Lean Six Sigma

Lean Six Sigma is a well-structured data-driven methodology that enables organizations to achieve effective and accurate outcomes repeatedly over a period of time. Let us help you improve manufacturing efficiency and quality, lower costs, enhance cash flow, reduce waste and ensure process stability.

We also offer Six Sigma Yellow, Green and Black Belt training that provides a cost-effective method to train and certify individuals in Six Sigma techniques.

IES excels in onsite customized six sigma training and applications ranging from 2 to 18 days. These engagements can include: leadership overview; project selection and scoping days, Six Sigma content training, coaching and mentoring days; body of knowledge examination; final project review and Six Sigma certification.

Toyota Kata

Toyota Kata helps develop creative, scientific-thinking skills. Employees can use these skills to keep improving, adapting, and generating competitive advantage in a strategically-aligned way. By practicing the Toyota Kata routines and patterns, anyone can become better equipped to navigate ambiguity and reach challenging goals.

IES offers a variety of services in Kata including both improvement Kata (IK) and coaching Kata (CK) and their applications. Kata implementation is ideal for companies who may not require a full Lean Transformation but still wish to reap the benefits of core lean tenants including respect for people and a problem-solving culture. Kata helps develop the bench strength in your organization through appreciative inquiry and a structured coaching model for kata practitioners and learners.

Training Within Industry

Training Within Industry (TWI) is a dynamic program of hands-on learning and practice, teaching essential skills for supervisors, team leaders and anyone who directs the work of others. It is an essential element of Lean and Continuous Improvement programs around the world including the Toyota Production System. TWI provides a foundation for fostering organizational excellence and transforming business culture.

IES Offers three standardized TWI programs addressing the essential skills needed by supervisors, team leaders, and trainers: Job Instruction (JI), Job Relations (JR), and Job Methods (JM).

Learn By Doing—Assures Skills are Applied. After the daily session, trainees return to the workplace to use the techniques learned and choose real-life examples to discuss and practice in class.

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