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Highlights of our full range of training courses / Workshops:Lean & Agile Supply Chain / Inventory Modelling Lean & Agile Manufacturing Planning & Control Operations Management / Team Leader Training Step Change Management / Business Process Reengineering Procurement (Purchasing & Supplier Management) Product Management / New Product Introduction / Quality Management
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Expert Systems / Tools:our unique 118 point agility self diagnosis
Relevant Further Reading: The following further articles were mentioned in this paper:a. Permanently Maintained Website Articles: Rough Cut Capacity Planning (RCCP) level 2 of the capacity management process "Lean Manufacturing" our definition
b. Previously Featured Articles from our Archives (Up to 2 per organisation available on request):
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Training Courses & Workshops to supportLean and Agile Manufacturing Planning and ControlOur Training Philosophy and Approach The following 21 training courses are available (linked to highlights below). They can be readily tailored to suit individual requirements for in-house workshops.
M01 Designing, Implementing and Operating Kanban Systems(2 days) ( Course Schedules), (Request course details) Designed for:Lean Manufacturing / JIT / Kanban / Pull system designers and implementation project teams, team leaders / department heads of manufacturing Course Objectives:Pull systems offer clear bottom-line benefits, if done properly. This detailed course will enable you to design, implement and maintain your own Kanban systems and deliver the bottom line benefits of:
Course Highlights:This course will show you how to:
Examples of course participant's feedback:
Note 1: A MS Excel template for calculating required Kanban population sizes is supplied with the course. Note 2: A copy of our Kanban & Lean Simulation Game toolkit (see M22 below) is included with this course. Note 3: A complete in-house task force lean manufacturing training programme is available for the reorganisation of manufacturing under JIT and Lean principles. See M14 Lean & Agile Manufacturing Detail (Pick & Mix) (below) Note 4: Based on our best project benchmarks
M02 Advanced Scheduling Systems (APS)(1 day) ( Course Schedules), (Request course details) Designed for:All levels of production planning and inventory management personnel Course Objectives:Choosing and getting the best from scheduling systems is the part of scheduling systems implementation that the software does not help and the software supplier may not be the appropriate person to ask. This detailed course, which is software independent, discusses scheduling from first principles up to advanced techniques and will enable you to select an appropriate scheduling system then design, implement & operate the system to deliver the bottom line benefits of scheduling with minimum administration. Course Highlights:This course will show you how to:
Examples of course participant's feedback:
M03 Bill of Materials and Routings Design & Management(1 day) ( Course Schedules), (Request course details) Designed for:All levels of product design, inventory management, production planning personnel and teams responsible for ERP / MRP implementation Course Objectives:Bill of Materials (parts lists / ingredients lists) & Routings (methods of manufacture) are at the heart of a manufacturing process. They not only define the product & process, they also provide a structure to manage ALL of your business processes, from purchasing to after-sales. Correct design and timely, accurate maintenance is essential and if done badly, a significant source of problems and inefficiency. Designed in conjunction with D02 Specification Change Management: (Managing Product, Computer Programme, Documentation, or Process changes), this detailed course will enable you to design and implement your own simple Bill of Materials and Routings and their maintenance processes to satisfy the potentially conflicting needs of design, materials planning, capacity planning, work-in-process tracking, product costing, inventory accounting, service and repair and last but not least, quality control. It also defines the key requirements of change control. Course Highlights:This course will show you how to provide the necessary degree of control whilst reducing administration across the business by:
Examples of course participant's feedback:
M04 Participative Master Production Scheduling (PMPS)(1 day) ( Course Schedules), (Request course details) Designed for:All stakeholders in the planning process including sales managers, operations managers / team leaders, supplies / purchasing managers, and planners Course Objectives:How do you satisfy customers AND utilise resources effectively AND meet the business plan? Two of the key requirements of out of the 15 we explain in this course are:
This detailed course, designed in conjunction with M05 Simple Capacity Planning & Control (below), is focused on the attributes of a best practice operations planning process in order to:
Course Highlights:This course will help you to:
Examples of course participant's feedback:
Note 1: This course is also available as an in-house workshop. When run with all the stakeholders in the room it produces an outline design and implementation task list. Note 2: This course assumes a passive role of the management of the sales & development processes. Our course SSC08 Participative Development, Sales & Operations Management in addition assumes an integrated Sales Management, & Product Development Process (e.g. Sales Planning) driven by a Participative, Development, Sales & Operations Management process.
M05 Simple Capacity Planning & Control(1 day) ( Course Schedules), (Request course details) Designed for:Master Production Schedulers, planners and operations team leaders Course Objectives:The simple objective at level 2 of the capacity management process is to create a "do-able" plan (& then do it "On-Time In-Full")! Firmly following lean principles, this detailed course, designed in conjunction with "M04 Participative Master Production Scheduling" (above) and "M11 Simple Ways to Maximise Output & Workflow" (below) will enable you to create; implement; and operate your own simple, low cost, capacity management process incorporating simple tools to:
Course Highlights:This course will help you to:
Examples of course participant's feedback:
Note: Includes our MS Excel Rough Cut Capacity Planning model template to get you started quickly
M06 Stock & Work in Process (WIP) Tracking(1 day) ( Course Schedules), (Request course details) Designed for:All levels of inventory and operations personnel, expeditors and teams responsible for ERP / MRP implementation. In short, everyone who moves work around. Course Objectives:Knowing what you have, how many, & it's current status, facilitated by controlling work in process levels, are not only key requirements of accurate production planning, but also of production control, with its goals to meet the plan and maximise productivity, whilst minimising lead-time and stock levels. This detailed course, (which is independent of software), will enable you to support accurate stores and work in process tracking processes by outlining modern, commonly used, control methods and by emphasising the importance of accurate recording in production planning & control in 4 modules:
Course Highlights:This course will show you how to:
Examples of course participant's feedback:
Note 1: A companion course for pure warehouse operations is SSC06 Warehouse Operations Management Note 2: M17 Stock & WIP Tracking for Beginners (below) provides a short introduction to this topic as part of an MRP "educating the critical mass" initiative (available only as an in-house workshop). Below are three MRP Training Courses, Beginner; MRP1; MRP2:M07 MRP for Beginners(½ day) ( Course Schedules), (Request course details) Designed as:An introduction to MRP systems and as a means of educating everyone connected with an MRP system Course Objectives:In order to deliver the bottom line benefits everyone who comes into contact with an MRP system needs to have a basic understanding of how it works; what data it uses; and the importance of data accuracy. As one Operations Director said to us, "they need to be reminded every 2 to 3 years too!" This detailed course, (which is independent of software) provides a short introduction to this topic, as part of an MRP "educating the critical mass" initiative, by providing an understanding of:
Course Highlights:This course will help you to:
Examples of course participant's feedback:
Note 1: An MRP1 simulation model is used to illustrate the effects of data in the system. Note 2: This course forms the first half day of M08 immediately below.
M08 Material Requirements Planning (MRP1)(1 day) ( Course Schedules), (Request course details) Designed for:All levels of planning, inventory management and operations staff and especially for teams responsible for ERP / MRP implementation, or trying to improve MRP performance and particularly valuable to people new to MRP Course Objectives:In principle an MRP1 system should be a Just In Time system. There are 3 exceptions (agricultural crops, products / processes requiring maturation, and strategic spares, the effect of which can be ring-fenced), but otherwise you should be able to achieve: an overall stock turn roughly equal to 1-2 times the process lead-time of a typical job that you are expediting through the process without queuing (E.g. If your overall manufacturing lead-time without queuing is 2 weeks, you should have about 2-4 weeks' worth of total inventory); with excellent customer service (>98% of customer orders / schedule call offs, On-Time-In-Full). (See Achievable Benchmarks) This detailed course, designed in conjunction with M09 MRP2 (immediately below), which is independent of software, provides a detailed understanding of MRP1 design, implementation and operation considerations. If your current MRP system is not achieving our benchmarks above, or you are about to implement your first MRP system, or you are new to MRP, this course is for you! Course Highlights:In addition to the content of M07 MRP for Beginners (above) which forms the first half day of this course, this course will help you to:
Examples of course participant's feedback:
M09 Manufacturing Resources Planning (MRP2)(1 day) ( Course Schedules), (Request course details) Designed for:All levels of planning, inventory management and operations staff and especially for teams responsible for ERP / MRP implementation, or trying to improve MRP performance and particularly valuable to people new to MRP2. Course Objectives:In addition to MRP1, MRP2 introduces a new level of potential benefits and sophistication into the scheduling of production. Whilst it adds more discipline to the management of work-in-process and integrates finance & purchasing, it also creates another layer of data to be managed. As a consequence good MRP2 implementations where plans are actually met (compliant) are still hard to find. Designed in conjunction with M08 MRP1 (above) which is a prerequisite, this detailed course, (which is independent of software), provides a detailed understanding of MRP2 design, implementation and operation considerations. Course Highlights:This course will help you to:
Examples of course participant's feedback:
M10 Simple Stock Control(1 day) ( Course Schedules), (Request course details) Designed for:All levels of inventory management and operations staff and especially for teams responsible for implementation of simple or lean and visual materials control systems Course Objectives:Simple, inexpensive, but very effective, stock control systems for repetitive items and consumables are an integral part and key requirements of a "Lean" / "Just In Time" implementation. But a common mistake in the use of these methods is that they are perceived as "fit-and-forget". Like all other control systems they require: appropriate selection; proper design; good implementation; and ongoing, but low cost, maintenance! This detailed course, designed in conjunction with M11 Simple Ways To Maximise Output & Workflow (below), firmly based on lean principles & which is independent of software, provides a detailed understanding of selection criteria; design, implementation and operation of simple, low cost, stock control and point of use / line-side stock replenishment systems. Course Highlights:This course will help you to:
Examples of course participant's feedback:
Note 1: Includes a simplified version of our Excel spreadsheet template for you to take away (This course and this template contains very basic content from SSC03 Advanced Forecasting & Inventory Modelling using spreadsheets) Note 2: Includes a brief introduction to Kanban systems for which a comprehensive and detailed course on Kanban / Just-In-Time is contained in M01 Designing, Implementing & Operating Kanban Systems (above)
M11 Simple Ways To Maximize Output & Workflow(1 day) ( Course Schedules), (Request course details) Designed for:Operations team leaders, operations staff and teams responsible for improving operations performance & useful for operations planning personnel. Course Objectives:More People, More Stock, More Equipment, More Control Systems, More Computers, do not necessarily equal more output, and hardly ever make work flow. They do, however, increase cost! This detailed course, designed in conjunction with M10 Simple Stock Control (above), firmly follows lean principles, to provide a detailed understanding of the design, implementation and operation considerations of simple, easily learned, tools, techniques and procedures to maximise output and workflow. Course Highlights:This course will help you to:
Examples of course participant's feedback:
M13 Manufacturing Accounting for Beginners(1 day) (Course Schedules), (Request course details) Designed specifically for:Junior, unqualified, finance, support staff working in a manufacturing environment, or others wishing to understand the principles and practice underpinning their finance systems Course Objectives:Junior, unqualified, staff in the finance department can make a significant contribution to profitability by recognising when things are beginning to go off the rails, not when the wheels are already off, (when the problem is bought to the attention of senior management). All you have to do is show them what to look for. This detailed course provides in laymen's language the underlying principles, practice and limitations of key aspects of financial control in a manufacturing business namely: The planning & control of expenditure:
Course Highlights:Topics covered include:
Examples of course participant's feedback:
Note: OM04 Finance for Team Leaders provides alternative content from a team leader's viewpoint
M14 Lean & Agile Manufacturing Detail (Pick & Mix)(1-28 days) ( Course Schedules), (Request course details) Create your own in-house workshops in your drive to improve your business from our range of lean & agile manufacturing training courses including:
M15 Agile Manufacturing Overview M19 How to become a "world class" manufacturer
Manufacturing Planning & Control:M01 Designing Implementing & Operating Kanban systems M05 Simple Capacity Planning & Control M11 Simple ways to maximise output & workflow M22 Kanban & Lean Enterprise Simulation Game SSC04 Production Planning & Control Back To Basics Continuous improvement:C01 Focused Improvement Systems C02 Setting Key Performance Indicators C03 Measures of Performance Detail C04 Continuous Improvement Basic Tools & Techniques Forming cells / teams:S02 Business Process Reengineering S13 Culture Development Methods Operations Management:OM01 Organising & engaging the team OM03 Organising & managing the workplace Supply Chain:SSC01 Tools Techniques & Modern Trends in Supply Chain Management SSC07 Strategic Supply Chain Management Product Management:D03 Six steps to near perfect quality
M15 Agile Manufacturing(1 day) ( Course Schedules), (Request course details) Designed as:An executive overview course Course Objectives:Leanness without agility simply leads to shortages! To be lean you have to be agile and to be agile you need to be lean. Lean initiatives target waste, whilst agility targets responsiveness! Designed to accompany your strive towards growth and profitability & aimed at all aspects of manufacturing businesses, (not specifically at operations), this course is intended to provide a road map to an Agile business. Course Highlights:This course will help you to:
Examples of course participant's feedback:
Note 1: This course includes a copy of our unique 118 point agility self diagnosis, to enable you to create your own Agile implementation task list. Note 2: Also see M14 Lean & Agile Manufacturing Detail (Pick & Mix) above
M17 Stock & WIP Tracking for Beginners(½ day) ( Course Schedules), (Request course details) Designed for:The novice or newcomer to managing inventory, warehouse and shop floor materials control personnel, and as a critical mass awareness workshop in MRP implementations or rescue projects Course Objectives:In the haste to ship product, the equally important task of maintaining the integrity of stock and work-in-process records sometimes comes a poor second. But this week's stock discrepancy is next week's lost output! Designed as an introduction to the topic and to sell the message of stock and work-in-process accuracy, this course identifies key sources of error and faulty processing, and motivates individuals to improve recording integrity. Course Highlights:This course will help you to:
Examples of course participant's feedback:
Note 1: A companion course for pure warehouse operations is SSC06 Warehouse Operations Management Note 2: A one day detailed & more advanced version of this course is available in M06 Stock & Work in Process Management, which should be viewed as a follow-on course for novices.
M19 How to become a "World Class" Manufacturer(1 day) ( Course Schedules), (Request course details) Designed for:All levels of management, team leaders and especially useful as a workshop for teams responsible for World Class implementation programmes Course Objectives:Leadership requires a vision. But a World Class vision without a plan will remain a dream! This course draws on strategic content from a number of our courses and our experience of implementing world class development programs in a number of industries to show you:
Course Highlights:This overview course, aims to provide an understanding of what world class is and a route map to achieve it. This course will help you to:
Examples of course participant's feedback:
Note: Includes a number of our diagnostic health checks
M21 Lean Manufacturing Detail(2 days) ( Course Schedules), (Request course details) Designed for:All of the management team (not just operations) and especially for teams responsible for Lean Manufacturing implementation and personnel expected to contribute to the implementation Course Objectives:"Lean Manufacturing" has been around for over 30 years now but how many manufacturing businesses do you know that are truly lean based on our definition? This detailed course aims to provide practical instruction in designing and implementing lean practices and processes. Course Highlights:This course will help you to:
Examples of course participant's feedback:
Note 1: A one day executive overview of lean manufacturing is available as an in-house workshop. Note 2: Also see M14 above
M22 Kanban and Lean Enterprise Simulation Game(1 day) ( Course Schedules), (Request course details) Designed for:Kanban & Lean implementation teams and specifically as a "train the trainer" workshop for onwards delivery to explain to operations personnel why Kanban / Lean is a better way Course Objectives:Kanban and Lean Manufacturing require the active participation of all employees. One of the key causes of failure we have observed (and rescue situations we have been involved in) is a breakdown in the simple disciplines required, caused either by a lack of understanding or lack of involvement of operations personnel. One step beyond the stickle-brick and beer games, this unique toolkit allows you to create a more persuasive Kanban and Lean Enterprise Simulation Game by simulating your own products and processes. Course Highlights:This one-day course, which includes a free copy of the Kanban & Lean Simulation Toolkit (described below) will enable you to discover for yourself:
To make this easier we already have adaptations of the game to suit a number of environments including: Machining; Mixing; Assembly (low volume & high volume); Waste disposal; Printing; Paper; Composites; FMCG's; Food & drink. The Simulation Game Tool Kit made up of five parts:
Examples of course participant's feedback:
M23 Capacity Management Foundation Course(2 days) ( Course Schedules), (Request course details) Designed for:Operations planning personnel, team leaders and supervisors Course Objectives:Having too many, or too few, of the required resources at the right time is always very painful and can be fatal! Getting the most from them is not trivial! This detailed, introductory course, will enable you to design and implement your own capacity management processes and evaluate the applicability of different capacity planning and control options in order to improve the processes which manage capacity and drive capacity improvement in order to:
Course Highlights:This course will help you to:
Examples of course participant's feedback:
Note 1: M24 Materials Management & Stock Control (immediately below) provides complementary content for planning personnel and together they form a solid foundation course for new planners and operations personnel. Note 2: This course includes overview and introductory content from courses M02, M04, M05, M11 above, & S02 Business Process Reengineering, S04 Strategic Capacity Management; S05 World Class Change Management; SSC08 Participative Development, Sales & Operations Management; OM02 Managing & Improving Individual Skills & Overall Skills Levels
M24 Materials Management & Stock Control Foundation Course(3 days) ( Course Schedules), (Request course details) Designed for:Operations planning personnel, team leaders and supervisors, and especially for newcomers to this subject Course Objectives:The now, well accepted, Just-In-Time philosophy is still a fairly rare, practical, day-to-day reality. This detailed, introductory, course will enable you to design, implement and maintain good materials management practice to consistently deliver excellent customer service with minimum effort and inventory. It includes overviews of current best practice thinking in materials planning and control systems and provides introductions to the most popular and effective ones. It will help you to:
Course Highlights:It covers the following topics:
Examples of course participant's feedback:
Note 1: M23 Capacity Management (above) provides complementary content and together they form a solid foundation course for new for planning and operations personnel Note 2: This course includes overview and introductory content from courses M01, M06, M08, M09, M10, M11, M15, M21, (All above). It also includes content from our Supply Chain Management range of courses including: SSC02 Materials Control Process Selection (which is in fact Day 2 of this course), and SSC04 Production Planning & Control: Back to Basics and SSC06 Warehouse Operations Management
A number of our other courses are also relevant to manufacturing companies. _______________________________________________________________ |
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Whilst great care has been taken to provide relevant, accurate, practical, advice based on our considerable process design and development experience, this will almost certainly require interpretation into the context of your unique business. Please be careful in doing so and if in doubt seek expert advice. We would welcome your feedback!
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