Training Plan

Lean Manufacturing Training Plan

Lean Resources

Lean Manufacturing requires significant training for everyone in the organization. A Training Plan is vital to your Lean Manufacturing Strategy. People will normally need training in three areas:

Team Processes
Process Design & Process Management
Task Skills

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 (as shown)

5. Determine resources (In-House or external)

6. Determine the timeframe for implementation by area and/or personnel category

7. Develop an initial schedule

When To Train for Lean Manufacturing

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.

The matrix below shows which people should normally attend our various programs. Columns to the right show when to conduct the training.

Who Conducts The Training?

Good trainers know their subject matter. In addition, they have had instruction and practice in training techniques. Few companies have these capabilities in-house, but they can be developed. Strategos can provide occasional training on specific subjects, long-term training programs, or we can develop your in-house training capabilities.

A Training Plan Example

The training plan shown below was developed for a manufacturer of commercial windows. Programs are listed in the two left columns along with the hours for each program. Remaining columns show categories of personnel. A letter indicates that particular people should attend a particular program. The letters also indicate priority with "A" being the highest. Columns on the far right accumulate hours. For this particular manufacturer, most people need 26 hours, or more, of training. This might occur over several years with ongoing programs for new-hires. In this firm, early emphasis is on Statistical Process Control (SPC) and Problem Solving. Priorities for other manufacturers might be different.