Dak Consulting

Developing Improvement Leaders

Telephone: 01491 845 504

Training to Black Belt Level
  • DAK Academy provides practical training for improvement leaders in organisations faced with the challenge of guiding front line, middle management and senior teams to deliver year on year improvement in performance. Course content is graded using the levels shown below to develop skills and confidence of 1. those who need a basic understanding (Yellow Belt), 2. those with the challenge of implementation (Green Belt) and 3. those who need to train others to implement improvement (Black Belt and Master Black Belt).           

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Beyond 5S - Improving Work Space Synchronicity 3 Day Workshop

Date: In House Training Workshop
Location: Your Plant
Cost: £4500 + VAT

5S is widely used to define individual workplace layouts but its true power is in the development of synchronised islands of activity covering both material and information flows.  A 3 day workshop with practical activities designed to take participants on a journey from disorganised to organised to workplace systems that support synchronicity and flow across the end to end value stream.

Workshop goais are

  • Learn how to lock in the gains of 5S
  • Understand how to engage those in the workplace with improving workflow synchronicity
  • Know how to build self manageed workplace processes
  • Be able to move beyond the theory of 5S to improve all aspects of daily working.

Learn how to lock in the gains of 5S by developing work spaces that sychronise all aspects of daily work including:

  • Recieving work instructions
  • Time management/work tracking
  • Materials, tools and spares management
  • Research/information finding
  • Dynamic workload balancing
  • Administration/QA
  • Control of compliance protocols

Understand how to engage those in the workplace with systematically improving Work Space Synchronicity to:

  • Increase work plan adherence 
  • Adapt to variability in materials, people and order flow
  • Efficiently incorporate agency/temporary personnel at times of peak loading
  • Simplify control and compliance
  • Reduce human error risks
  • Release of management and support personnel from day to day activities to focus on higher added value tasks.

This 3 day workshop covers the theory and practice of work space design and the practical steps to deliver self-managed work processes. Processes that are easy to do right, difficult to do wrong and easy to learn.  The outcomes includes:-

  • Simplified, more resilient shop floor production, maintenance, planning, quality assurance and training processes.
  • Transfer of management and support function standard work to front line teams
  • Improve door to door quality cost and delivery performance
  • A customised roadmap to guide the journey from passive to sychronised workspaces.

The course includes hands on workspace design activities using MiniTec shop floor fixtures and fittings so that participants can learn through doing.

Who should attend?

For managers, team leaders and change agents tasked with the reduction of shop floor waste and non-value added activities through the engagement of shop floor personnel with the improvement of:

  • Work place systems and procedures including planning, booking in, kitting, material control;
  • Workplace layout, organisation, flow and productivity;
  • Rapid customer order fulfilment cycles;
  • QA checks, in process testing/auditing;
  • Training of personnel including temporary worker's/agency staff.

Workshop Approach

This will include the developing solutions around:

  • The design and location of safety guards, enclosures, workstations, conveyors and transfer systems to simplify production processes, reduce waste and improve flow;
  • The creation of work place which transfers ownership of the territory to those who work in it;
  • The use of Daily Management as a lever for change and engagement as a vehicle to develop high performance teams.

This combination of theory and practice guides through the journey from passive to synchronous workplace design.

DAY 1 - Understanding shop floor reality

  • What does good look like?
  • What are the wastes
  • Why do they occur
  • The management dilemma
  • Control vs Engagement
  • Understanding behaviours and engagement
  • The principles of engagement
  • The steps to high performing teamwork
  • Understanding production processes
  • Direct and indirect activities/standard work profile

Syndicate Briefing

Participants work in small teams using to apply improvement tools and techniques to mini improvement projects on the LG Motion shop floor using Minitec aluminium profile shop floor "furniture" to experiment with and refine layout options.

DAY 2/3

Step 1: Take Control

  • Assessing current design
  • Understanding the shop floor reality
  • Wastes, trouble map, priorities
  • Standardisation
  • Resilience and flexibility
  • Clarifying normal conditions
  • Coordination, feedback, skill levels
  • Assessing visual management Information, Instructions, Knowledge
  • Setting improvement measures and priorities

Step 2: Get organised

  • Developing and refining layout options
  • Task design and integration
  • Material and information flows
  • Training programme design and delivery.
  • Improving daily management and Management/Team Standard work
  • Developing and tracking the business case

Step 3: Get Better

  • Engaging shop floor personnel
  • Setting accountabilities, getting team engagement
  • Reinforcing Change: tracking progress, giving recognition
  • Raising Quality, Cost and Delivery performance
  • Capture and resolve the causes of defects and human error
  • Optimising working practices
  • Develop a practical 90 day action plan
  • Defining a realistic and achievable 12-month outcome
  • Developing first step
  • Delivering results

Review of the Workshop
Benefits, Concerns, Q&A

Led by Ian Weare of DAK Consulting

Ian's early career for a leading automotive component supplier included roles as engineer, team leader, manager and change agent. This has provided the practical foundations for his success as a coach and advisor to global industry leaders including BP, Coca Cola and Honda. He has developed a unique set of learning and skill development tools to explain difficult concepts whilst having fun. His challenging but supportive approach combines relevant theory with practical activities to develop insight and confidence to act.