The Lean Learning Center was founded in 2001 to address the gaps and barriers that are holding back companies from successful and sustainable lean transformation. In addition to the advanced curriculum, the Center has developed a learning environment designed specifically for adult learning utilizing techniques that include discovery simulations, case studies, personal planning, and reflection – ultimately engaging people at a deep and personal level. We bring our unique lean understanding in creative ways to executives, managers, supervisors, change agents and front-line employees. The Lean Learning Center is a Troy, Michigan-based organization that helps organizations transform themselves through lean tools and methods.
Many organizations complain about having difficulty maintaining standards on the shop floor. We often make improvement only to find the process regresses back to its previous state in a short period of time. A closer look at the audit process will often show the following types of symptoms: Standard work is posted, but no one is following it. The sequence, timing, and content of work changes within each operator as well as from one operator to another. There are inconsistencies in incoming materials that cause over processing at the workstation and overburden to operators. This may lead to defects and operational delays. Poorly designed products and processes that cause unevenness and overburden. 5S is not maintained or consistent between one shift and another. Uncontrolled tools and materials are squirreled away in cabinets as a result of hoarding for just in case reasons. Non-conforming materials are not properly identified which exposes the operation to risk. These issues may indicate a general lack of management oversight of the process. Management oversight may typically occur in the form of system audits, control point checklists, or other structured reviews of the operation. An audit is essentially a check on the system to see that activities are [...]