The Training Plan & Lean Strategy
training should not be an afterthought though, it frequently
is. Lean fails more often over human issues than technical
errors and training is one way to cope with human issues.
Training is essential to develop
the required knowledge and skills for Lean Manufacturing. It also helps develop a corporate
culture that is conducive to and enables that lean strategy.
The development of a company training plan that
covers essential skills for all employees should be a part of every Lean Strategy and
the implementation plans for
People will normally need training in three
How To Develop A Training Plan
1. Determine which
elements of Lean Manufacturing are applicable and prioritize
2. Categorize the
people into logical groups with similar training needs
3. Identify programs
and time requirements for each program
4. Construct a matrix
5. Determine resources
(In-House or external)
6. Determine the
timeframe for implementation by area and/or personnel category
7. Develop an initial
When To Train for Lean Manufacturing
Training should address the
how as well as content.
Lessons unrelated to work are
ignored; too-early lessons forgotten;
too-late lessons resented.
People rapidly forget the information from formal
learning unless they begin to use it right away. After two weeks, most people retain about 30%
of learning. It is important, therefore, to conduct training immediately before the trainees
will begin to use their new information and skills. This is especially true for subjects such as
SPC and Teamwork.
Some training, provides background information and
skills that will be necessary through the entire journey to Lean Manufacturing. Leadership and
introductory programs are examples. Such training is normally done near the beginning of an
implementation but timing is not usually critical.
Other training is specific to certain implementation
steps such as Setup Reduction (SMED) or commissioning of a workcell team. Here, timing is
critical and training should occur immediately before a particular task begins.