In the current changed times for the near future businesses are/will be coming under increasing strain to deliver more with less. This is driving management to explore alternative ways of running their businesses.

 

For increasing numbers of businesses around Ireland, Lean is that alternative management system. Lean is a way of collective thinking to methodically stamp out waste whilst maximising value. It requires workers to transition from a singular focus on doing the daily work to a dual focus of doing the work AND being motivated to doing the work better every day. This necessitates the development of employees at all levels who think deeply about their work in order to understand the shortfalls and develop improved methods.

 

Green Belt attendees work on real-world business improvement projects to be implemented over the duration of the course and in the weeks thereafter. Past Green Belt projects delivered across Midland’s businesses between 2021 and 2024 have demonstrated significant costs savings (€15,000,000) and value to the bottom and top line over the duration of the Green Belt workshops.

 

In the course you learn what True Lean comprises in the context of quality and effectiveness improvement. The course covers key practices and how to lead during a Lean intervention including management of change and frontline culture enrichment over a 5-day classroom workshop. This deep dive training is designed to change mindsets in the organisation and enable keen awareness of the sources of hidden waste in the delivery your company’s products and services.

 

There is high emphasis on systematic problem solving and root cause analysis. Scope out and deliver a high impact project for your business in a 1-day workshop (on day 5).

 

Successful projects teams will be awarded Lean Management Green Belt Certification each upon project delivery.

 

Outcome: Practical working knowledge of the Lean Management System and a circa €25- 50K year on year collective savings potential from the delivered Green Belt project per delegate or group of delegates.

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Day 1 - Lean Management System

•  Lean Management & Six Sigma Overview

• The Science of Improvement Overview

• Appreciation of a System

• Understanding Variation

• Theory of Knowledge

• Human Side of Change

• The Integration of Lean and Six Sigma

• Rapid Tests of Change: PDSA Cycles Exercise

• 13 Forms of Operational Waste

• Waste Exercise & Video

• 72 Change Concepts

• Working with Teams

• Generic and Proven Roadmap for Successful Organisational Wide Transformation

• Sustain the Gains: Daily Management System

• Nurturing of the Improvement Culture

• Behavioural Standards

• Lean Leadership & Coaching

 

Day 2 - Core Improvement Practices

•  Overview of Methods and Tools

• The 4 Rules in Use (The DNA of Operational Excellence)

• Process Mapping

• Mapping Exercise

• 5S Workplace Organisation and Simulation Game

• Visual Management

• Quick Changeover

• Standard Work using Training Within Industry (TWI)

• Accelerated Idea Workshop

• Kaizen Event: AIE Workshop

• Mistake Proofing

• Waste Walks

• Management of Change

• Select and agree on projects (and sponsors) to be worked on for Green Belt Certification Award

 

Day 3

•  Project Progress Checkpoint on current state analysis

• Ideal State Map of Our Projects

• Future State Map of Our Projects

• Mapping Comparative Box Score

• Blueprint for Change Implementation Plan

• Agreement on project progress steps for review

 

Day 4

•  Project Progress Checkpoint on implementation plan

 

Creativity and Innovation Practical Workshop

• What is Creativity and Innovation? Two different things?

• Why do we need it?

• The Psychology of Creativity

• How to Spot Opportunities and Enhance Personal Creativity

• Most Commonly Deployed Engineered Creativity Practices and Practical Worked Group Exercises in non-work and work related scenarios

• How to Apply this Workshop to the Daily Work?

• Agreement on project progress steps for review

 

Day 5 - Project Practical Workshop (tying the projects all together into A3’s)

•  Who owns the problem?

• What is the problem?

• What are the symptoms? Impact?

• What is the background - What are you talking about & why? What are the current conditions?

• What are the root causes of the problem?

• What is the specific improvement in performance you need to close the gap?

• What are possible countermeasures for the problem?

• How will you choose which fix to propose?

• What is the cost and benefit of the selected countermeasure?

• What is the implementation plan and schedule?

• How will you know if your plan is working?

• What problems are likely to occur during implementation?

• How will you ensure follow up & continuous improvement?

 

Open Book Exam and Project Report Out on Day 5

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