As a regional member of the NIST MEP (Manufacturing Extension Partnership) TDO has the ability to deliver various programs on Lean Manufacturing in classroom settings. Our preferred method of delivery provides the learners not only a simulation, but a hands-on interactivity with a real issue at their facility. We strive to allow clients to participate in every implementation session with actual issues and projects. Many of the below listed programs are best utilized in an overall lean system implementation with a culture that supports continuous improvement ideals. At TDO we recognize that changing methods, methodologies and culture is not an overnight experience, and does not always come easily. Utilizing our resources and those of the 200+ member organization NIST MEP network, we can provide a customized solution to members of the Central New York Region to help with Lean, Six Sigma and Quality System implementations. Contact us at lean@tdo.org for a free on-site evaluation or a listing of any upcoming open enrollment sessions.

Lean Overview (Lean 101)
The overview session is designed to give an overview of lean manufacturing techniques and tools in a learn-by-doing atmosphere of a 4 'shift' simulation. The 1st round of the simulation is based on what a typical batch manufacturing company encounters in its day to day activities. Several tools including Standardized Work, Job Instruction 5S and Visual Controls are introduced before the 2nd round of the simulation is begun. Utilizing several of the newly introduced tools, the participants make improvements to the process and improve the bottom line. After the 2nd round, several more lean tools are introduced. These included Point Of Use Storage, Quick Changeover and Quality at the Source. Utilizing these newly introduced tools, the participants again make process improvements that are reflected on the bottom line performance. After the 3rd round, you are introduced to several more lean tools that include Pull, Kanban, Cellular flow and Total Productive Maintenance. The participants are then utilizing as many of the tools as they can to further improve the process which reflects directly to the bottom line results of the company in the simulation.
This simulation is a great introduction to the lean tools and how to use them with hands-on activities. We find that when several individuals within a company participate in the simulation, they immediately can relate how to use these tools on their own jobs. What the simulation can not demonstrate is how beneficial lean can be as an overall system as opposed to a series of tools that work independent of one another.

5S
Participants learn the concepts of the 5S System and then apply them to transform a cluttered, disorganized area into a clean, organized and orderly workplace. The course offers an opportunity to experience first hand how the 5S system reduces waste and improves productivity and quality in a simulated production facility. Participants will learn to describe the difference in workplace appearance and functionality before and after the 5S process has been applied. Participants perform an in-depth audit of workplace organization and standardization; organize a workplace by applying the concepts of sort, set-in order and shine; standardize procedures to maintain and control an organized workplace using visual controls; and describe how 5S can help to improve workplace environmental health and safety.

Value Stream Map (VSM)
Value Stream Mapping (VSM) is used to create a material and information flow map of production processes and the relationship between various levels in a multi-tiered suppy chain. Participants learn to: Map material, information, and supply chain flows Map current and future states; participate in a simulation; Present fundamental concepts of visual schematic diagramming devices; Provide practical, real-world applications for the course content; Facilitate the process of identifying systemic waste in order to visualize a waste-free future state; Prepare for Kaizen events.

Cellular Design
You'll learn the concepts of Cellular/Flow Manufacturing. Then, you'll help transform your traditional batch production area to a cellular layout and see the dramatic changes in the way the product flows, so that customer demand is met-on time, every time.

Visual Controls
This seminar provides a conceptual understanding of the visual workplace as well as an overview of the methodology for implementing and sustaining visuality throughout the enterprise. The seminar properly positions the technologies of the visual workplace - as a powerful partner to a company's journey to excellence and crucial to its ability to maximize lean results. With visual order (5S) in place, an organization is then ready to move on to more advanced visual applications: visual standards, visual displays, visual metrics, and beyond. Learn about the crucial link between visual and lean. Attendees will explore examples of visual solutions from workplaces.

Kaizen
A Kaizen event is a hands-on series of activities following a the structured Shingijutso method of Documenting Reality, Identifying Wastes, Planning Countermeasures, Implementing Changes, Verify Changes, Quantify Results and Make Standard. This cycle will be taught and facilitated on a targeted area as defined with the Value Stream Mapping reinforcing the training delivered in that module. The Lean tools of Kanban, Flow, Error proofing, and Hanedashi will be used in hands on activities that will reinforce the Lean 101 workshop and facilitate the staff to continually improve their process using the lean tools.

Total Productive Maintenance
Learn about Overall Equipment Effectiveness (OEE) and how it is related to capacity. The ten-fold effect of 5S techniques when applied to your equipment. The six major equipment-related losses, how to find and eliminate 4 of the causes of 75% of equipment breakdowns. Participants will apply the techniques on our simulated equipment in the classroom. By the end of the session, you'll experience how these techniques achieve dramatic improvements in uptime and increased equipment effectiveness.

Quick Changeover (SMED)
This workshop will teach the principles of Setup Reduction and the Single Minute Exchange of Dies (SMED) system. The Changeover Improvement Process will be applied to achieve setup reduction in a exercise. By the end of the session you'll experience reduced costs and setup times and see machine capacity increase at the same time.