Lean Manufacturing
Training Home Page

Bill Gaw

Who is Bill Gaw?

And why should we
listen to him?


lean manufacturing principles and techniques training

The Lean Manufacturing,
Seminar-in-a-Box
(Includes Train-the-Trainer Manual)

lean manufacturing game
 

Why Most Lean Manufacturing Initiatives Fail to Meet Expectations


Article: Shop Floor
Control 4 of 5

privacy policy

987

760-945-5596

Lean Manufacturing Simulation Game

Other Training Options:

Lean Manufacturing Training Package

Lean Manufacturing Transformation Training

Lean Manufacturing Assessment

Lean Six Sigma
Training Program

Lean Manufacturing
Simulation Game

Lean Manufacturing Certification Pogram

Manufacturing Management
Development Program

Operational Excellence Training Package

Lean Manufacturing
Consultants

Lean Manufacturing Seminar-in-a-Box

Kaizen Event Training

Lean Manufacturing, Seminars

Supply Chain Management Training

Strategic Planning
Training

Thinking-Outside-the-
Box e-Book

Lean Six Sigma PowerPoint
Presentations

Lean Manufacturing PowerPoint
Presentations

Lean Manufacturing
Articles

A primary reason for a lean transformation failure is lack of effective training. It's not an "add water and stir" business process. You can't just decide one day to become lean and think it will happen overnight. You need to determine what constraints are impeding your ability to increase speed, improve quality, and eliminate non-value-added activities. And, then you need to develop and implement lean concepts and tools for identifying and eliminating their root causes.

Why Most Lean Manufacturing Training Fail to Meet Expectations

The first challenge of a training program is how to rally company-wide support of and commitment to its lean manufacturing initiative. To achieve that, your Lean Manufacturing Training Package must first and foremost communicate the need for the change, the involvement required, and the need for a company-wide commitment. Simulation exercises demonstrating the "before and after" the initiative are an excellent solution to this challenge.

Lean Manufacturing,
Seminar-in-a-Box

Part No. 1: The Lean Manufacturing Simulation Game

Communicating the need, gaining involvement and commitment

     What I hear... I forget, 
                               What I see... I remember,
                                                         What I do ... I understand

The lean manufacturing simulation game" adds pizzazz and effectiveness to a company's training program and gains company-wide commitment and support of their lean manufacturing transformation.
 

Detailed instructions that describe how each exercise is set up and carried out. Also instructions on what non-participants should be watching and recording for the "after game forum."


What Manufacturing Leaders and
Their Teams Need to Understand and Master

*  How to convert a "push" into a "pull" manufacturing systems
*  How to eliminate shop floor chaos and workplace stress
*  How to introduce and apply demand flow technology
*  The power of sequential production and point-of-use logistics
*  How to move from "firefighting" to proactive problem solving
*  How to implement a sustainable, lean manufacturing initiative
*  How to reduce scrap, rework and work-in-process inventory
*  How to think-outside-the-box... creative thinking at its best.

 

Your Lean Manufacturing DIY Training Package is initiated by hands-on participation by teams that will setup MRP and lean  production factory simulations for comparing the effectiveness of two distinct production methods:


Game Process Synopsis 

Active participation for 6 to 12 people with sideline observation note taking by up to 20 observers.

Teams build 20 Lego Towers in two configurations from 320 multi-colored LEGO Bricks. A timer records the cycle times and observers record pros and cons of the two methodology (MRP and LEAN).

MRP (Push) simulation includes stockroom, shop order picking and subassembly production. Time to complete: 25-45 minutes depending on team skill level.

LEAN (Pull) manufacturing simulation sets up a "one- piece" flow production line using JIT and kanbans. Time to complete: 15-25 minutes depending on team skill level.

A  most important 30 to 60 minute, post-forum initiates a discussion of the pros and cons of each methodology. This is where the learning process takes hold.

 

The Lean Manufacturing Simulation Game is a demonstration of how sequential production and point-of-use logistics can turn a marginally successful product line into a huge winners.

Cycle Time Management is demonstrated and recorded, pros and cons of each methodology recorded and a post exercise forum drive home the lean manufacturing paradigm. 

Simulation Exercises are easy to set up and facilitate. Detailed instructions for each are included for each of the exercises. And, the creator, Bill Gaw, is only an email away should you have any questions.

Most Lean Manufacturing Training Packages fail to meet
expectations... we guarantee that our package
will exceed your expectation or
you'll get a full refund.


A customer saying it even better than we can:

Bill, 

Thank you for your permission.  We have already purchas-ed and used the lean Manufacturing Simulation Game and have found it of great value in demonstrating lean concepts.

John Bursill, Manager Manufacturing Services, INNOVEN
 

Lean Manufacturing,
Seminar-in-a-Box

Part No. 2: : Bill Gaw's "8-Basics of Kaizen Based Lean
                        Manufacturing Tutorial

Do you want to:

1.  Become a better team member/leader/manager/executive?
2.  Focus your energy on the significant issues?
3.  Transform your work environment from drudgery to fun?
4.  Minimize your day-to-day stress level?
5.  Master the BASICS of lean manufacturing?
6.  Exceed your goals and expectations?
7.  Gain recognition, promotions, and salary increases?

Does your company want to:

1.  Improve customer responsiveness and satisfaction?
2.  Optimize MRP/ERP and manufacturing processes?
3.  Increase speed and improve quality?
4.  Eliminate non-value-added costs?
5.  Eliminate the high cost of overtime, scrap, and rework?
6.  Improve customer on-time delivery of high quality products?
7.  Gain control of inventories and optimize their turnover?
8.  Increase team contribution to the company's "bottom line?"

If you answered yes to any of the about questions, you're time spent on this Web page will be a very valuable investment.


If you've ever said, "There must be a better way." 
... there is, and it's not more computerization!

In their efforts to draw closer to customers, many manufacturers have lost focus on what should be a company’s primary success factor – mastering the basics of their business and profession. Like Vince Lombardi, who achieved success by having his team focus on the mastery of football basics, we need to have our manufacturing teams identify and master the basics of lean manufacturing. No lean manufacturing transformation will exceed expectations without indentifying and mastering the 8-Basics of Kaizen Based Lean Manufacturing™.

 Lean Manufacturing Basics

"Do you want to optimize your lean transformation success? If so, you need to identify and master the basics of lean manufacturing. Many historic, recurring day-to-day problems (perhaps the same problems that plague your operation) can be permanently eliminated by a tenacious execution of Bill Gaw's "8-Basics of Kaizen Based Lean Manufacturing™."   

     Lean Manufacturing Transformation Training via Bill Gaw's, PowerPoint-Plus, Training Tutorial: The "8-Basics of
Kaizen Based Lean Manufacturing" (KBLM)

   *  8-Basics for eliminating part shortages
    * 
8-Basics for improving inventory utilization
     * 
8-Basics for reducing scrap and rework
      *  8-Basics for improving on time deliveries
       * 
8-Basics for improving customer satisfaction
        * 
8-Basics for eliminating non-value-added costs
         * 
8-Basics for exceeding goals and expectations
          * 
8-Basics for creating a fun working environment
           * 
8-Basics for earning recognition and rewards
            * 
8-Basics for reducing work place stress.
 

The 8-Basics of Kaizen Based Lean Manufacturing™

Kaizen Based Lean Manufacturing™ (KBLM) does not replace the MRP system but rather optimizes its shop floor and purchasing sub-systems. KBLM methodology can generate two to three times MRP cost reductions while producing significant improvement in quality and customer satisfaction.

Below is a graphic that shows the impact of optimizing MRP shop floor and purchasing sub-systems with Bill Gaw's KBLM methodology:

Lean Manufacturing Typical Results

An OEM company's Lean Manufacturing Transformation: 

Lean Manufacturing Actual Resluts

"Make-a-Difference" Lean Manufacturing DIY Training

For more than 13 years, our 1700 plus Customers and 15,000 plus MBBP Bulletin Subscribers have looked to Bill Gaw as a trusted developer of Power-Point-Plus tutorials and training programs. Training materials that help improve the spirit and performance of individuals, teams, and organizations.

Most training materials today are Videos/Webinars that tell you what to do but with very little practical implementation and/or optimization “know how.” Videos/Webinars present their story at a fast pace but most viewer’s retention rate is less than 25% and videos and webinars  perform poorly as a reference document.

Bill Gaw's tutorials and training modules on the other hand include powerful, Power-Point charts and graphics, "plus" annotated note pages with "slide commentary" and "lessons learned" by a "been there, done that" operations professional. A value added, learning experience on "how to" design, implement and optimize a lean manufacturing initiative for individual and company success. 

Our customers study the tutorial and T-modules content, print relevant sections, and highlight passages that are important to understanding and executing their change initiatives. The resultant blueprint is used for training and empowering their procurement team in their pursuit of inventory and supply chain performance objectives. Videos/Webinars don’t provide the same capabilities and their performance results are minimal.

One of the  keys to success is having a great coach. Whether you're in the trenches or working your way up the company ladder, the experience of someone who's "been there, done that" can be invaluable. Throughout his training  material  Bill Gaw provides expert knowledge, support, empathy, respect and most important, the wisdom of experience. And, he's always just an email away.

Another plus is that your training package will include a "Train-the-Trainer" Manual should your training leader needs some help in facilitating "make-a-difference" training secessions.

 


Below is an example of a PowerPoint-Plus
slide with its relevant note page:


Note Page

Without data, you’re just another opinion. That says it all. To continuously improve our processes, we need to first learn how to capture and then apply statistical data to our situation analysis. This action is a primary requisite to effective problem solving. Slide 3-3 presents an overview of a management by facts system.

Lesson Learned: The more that people use real time data to perform situation analysis and to establish and track corrective actions, the more comfortable and effective they become at interpreting and applying data-on-the-run. It is my contention that exceptional leaders make quick and quality decisions because they have mastered the skill of interpreting data-on-the-run.

However, when a leader says, “That doesn’t sound right to me. What about .. . . .?” He has put to use, what I call, the test of reasonableness and this ability separ-ates the exceptional leaders from the pack. To develop the ability to apply the “test of reasonableness,” a leader must first become an expert at interpreting data-on-the-run. The following slides will show you how.
 

A Huge Learning Difference

If you were watching a video, attending a seminar, or a webinar would you be able to take down the above in your notes for later reference... I don't think so. With Bill Gaw's approach, there is no need to take notes because you have the training slides, slide commentary, and "lessons learned" for future reference and organizational training.
 



 


Lean Manufacturing Transformation Training
It's the "how to" that really counts!

"Bill Gaw's training is focused on the "how to." Unlike other training  material that tell you only what you need to do... Bill's training presents what you need to do and then he shows you how to do it.                                      
                                    T.J. Imholte, VP Integrated Systems
                                                  Advance Storage Products

"Bill is one of the most prolific individuals in the consulting industry and profession. He is a true thought leader and a great coach -- one of the best. His advice is golden and he has the respect of his colleagues worldwide. We all religiously read his articles and news-letters because they are informative, educational and right on the mark."                                   

            Phil Andrews, Business Development, Project Manager
 

Lean Manufacturing, 
Seminar-in-a-Box

Featuring Bill Gaw's Manufacturing Simulation Game and his
"8-Basics of Kaizen Based Lean Manufacturing" Tutorial

To help you realize the full benefits of your Lean Manufacturing DIY, Seminar-in-a-Box it  includes the below training materials:

1. Lean Manufacturing Simulation Game

2. CD - Tutorial: 8-Basics of Kaizen Based Lean Manufacturing

3. CD - Strategic Planning T-Module Strategic planning is a business process that many companies employ to identify their strategic objectives and critical success targets Establishing Lean Manufacturing as a strategic planning objective is a major step toward reaching a company's full growth and earning potentials.

4. CD - Thinking Outside the Box e-Book - Creative thinking skills are required by everybody. Each and everyone needs to continuously challenge and expand their ways of thinking to enhance personal and business success.

5. CD - Value Stream Mapping T-Module -  Maps and flowcharts help make work visible. Increased visibility improves communication and understanding, and provides a common frame of reference for those involved with improving business and work process. Value Stream Mapping and Gap Analysis should be the first step to the implementation of Lean Manufacturing.

6. CD - Kaizen Manufacturing T-Module -  If your business team can handle only one strategic initiative at a time, then let it be the implementation of a “quick-hitting” continuous improvement  initiative. There just isn’t any other more important package in our pursuit of profits.

7. CD - Quality System Toolbox - Provides an interactive ISO 9001 checklist and quality manual and procedures to jump-start or re-ignite a company's quality manufacturing initiative. Provides a quality manufacturing roadmap to optimize prior quality efforts and maintain a focus on improving quality.

8. CD - Train the Trainer Manual - A copy of an effective training methodology, a vital train-the-trainer resource


Another customer saying it
even better than we can:

"Your manufacturing training materials are the easiest and fastest way to understand the practicalities of manufacturing success that I have seen in many years of management consulting activity. I intend to use them in my practice, if you
are agreeable, since I am now extending into new consulting areas."
       
       Luis Nascimento, DMA Consultores, Porto, Portugal

 

What Does It Cost?

Much less than you would imagine. In fact, we make the  "Lean Manufacturing, Seminar-in-a-Box" affordable so that it can fit easily within your company's training budget. We want you and your company to have the best Lean Manufacturing Training Package available and the best way to do that is to make it affordable.

1. Manufacturing Simulation Game (Price $496.00)

2.  CD, 8-Basics of Kaizen Based Lean Manufacturing (Price $396.00)

3.  CD, Strategic Planning Training Module (Price: $67.00)

4.  CD, Thinking Outside the Box (Price $67.00)

5.  CD, Value Stream mapping (Price: $67.00)

6.  CD, Kaizen Management (Price: $67.00)

7.  CD, Quality System Toolbox (Gift)

8CD, Train the Trainer Manual (Gift)

A $1160.00 value...  discounted $564.00 for
a
Special Price of only: $596.00


The Lean Manufacturing, Seminar-in-a-Box

$596.00

Order your Lean Manufacturing DIY, Seminar-in-a-box today at a special price of only $596.00.  That's a 49% savings and thousands of dollars less than the price of attending a relevant workshop. With Mr. Gaw's game instructions and training module expert commentary and "lessons learned" it's like having a Lean Manufacturing Champion,  guide you personally through his Lean Manufacturing methodology. And, you'll have all the training materials for future reference; not just a memory of the last seminar/Webinar.

Interested in only the
Manufacturing Simulation Game

If you wish to order only the game, scroll down the page to: "Three Ways to Order:"

Interested in only the Tutorial:
8-Basics of Kaizen Based Lean Manufacturing

If you wish to order only the T-Modules, scroll down the page to: "Three Ways to Order:"


 

Lean Manufacturing,
Seminar-in-a-Box

Manufacturing Simulation Game and 8-Basics of Kaizen Based Lean Manufacturing Tutorial have helped individuals and companies:

*  Better understand how to integrate lean manufacturing with MRP
*  Implement sequential production and point-of-use logistics
*  Transform manufacturing training and learning from drudgery to fun
*  Identify and master the basics of "flow technology"
*  Develop a proactive, self-empowered manufacturing team
*  Create a highly productive and fun working environment
*  Increase speed, improve quality and reduce costs
*  How to move from "firefighting" to proactive problem solving
*  Eliminate the root cause of shop floor chaos and workplace stress

For more than 14 years, Our Customers have looked to Business Basics as a trusted developer of manufacturing training materials, seminars, and workshops. Training options that help improve the spirit and performance of individuals, teams, and organizations.
 


Another customer saying it
even better than we can:

"Bill Gaw's Lean Manufacturing DIY Training Package is focused on the "how to." Unlike other training materials that tell you only what you need to do... Bill presents what you need to do and then shows you how to do it."
                                
                                T.J. Imholte,
VP Integrated Systems
                                             
Advance Storage Products  
 

Do you want to:

*  Become a better team member/leader/manager/executive?
*  Focus your energy on the significant issues?
*  Transform your work environment from drudgery to fun?
*  Minimize your day-to-day stress level?
*  Master the basics of lean manufacturing process?
*  Exceed your goals and expectations?
*  Gain recognition, promotions, and salary increases?

Does your company want to:

*  Optimize MRP/ERP and manufacturing processes?
*  Increase speed, improve quality, and non-value-added costs?
*  Eliminate the high cost of overtime, scrap, and rework?
*  Improve customer on-time delivery of high quality products?
*  Gain control of inventories and optimize their turnover?
*  Increase team contribution to the company's "bottom line?"

Our Guarantee Says it all

We are so sure that your Lean Manufacturing, Back-to-Basics, DIY-Training Package will have the impact you desire that you can order entirely at our risk. The Lean Manufacturing, Seminar-in-a-Box comes with a No Risk, 100% Unconditional Money-Back Guarantee. This is a Lifetime 100% Money- Back Guarantee!  

 

Believe this, we will never consider your purchase binding until you have used  the Lean Manufacturing, Seminar-in-a-Box and put it into practice. We know that you, like our other customers, will be thrilled with the results. In fact, we are so convinced that your Lean Manufacturing DIY Training Package will work for you that if you aren't completely satisfied for any reason at any time, simply return only the LEGO game for an immediate refund of your purchase price. You simply can't lose.

Remember, if you continue to work the same way, you're going to get the same results. The next move is up to you. I've shown you that our training tool is as risk free as an offer can come. You and I know that if you've read this far, you're seriously interested in improving your manufacturing training package and helping yourself and your company achieve their full growth and earnings potential.

 

 
ORDER NOW BONUS No. 1 

Push vs. Pull Video: If you order during this special September offer, we will include a classic, humorous lean manufacturing video. This is the famous "Oldie but Goodie" HP video that demonstrates: Push vs. Pull systems, one-piece-flow,  stockless production, and cycle time management. It helps transform MRP supporters into lean manufacturing advocates and champions.


 

 

 
ORDER NOW BONUS No. 2 

Free Shipping and Handling... If you order during this special offer,  shipping and handling are free. We'll send confirmation by return email and ship your order via USPS priority mail and you'll have it in your hands in 3-4 days, (domestic shipments).
 

Three Ways To Order

To order by credit card: If you place your order via our secure order form, shipping and handling are free. We'll ship your Lean Manufacturing, Seminar-in-a-Box via USPS priority mail. We'll send confirmation by email and you'll have your training package in your hands in 3-4 days (domestic shipments). To place your order, simply click on the blue bar below the credit card icons: 

 

The Lean Manufacturing, Back-to-Basics,
DIY-Training Package:

 


The Lean Manufacturing Simulation Game only

 


Tutorial: 8-Basics of Kaizen Based Lean Manufacturing
(Download File)

 

To order by phone: call us at 760-945-5596.

To order by purchase order: simply email us your purchase order number and shipping instruction. We'll send confirmation by return email.


The Ball is in Your Court

If you think this training will help your company but you're not in a position to make the final decision, may I suggest that you forward this Web page to the decision maker. He/she may thank you for your interest and initiative.

For your initiative, we'll send you a copy of our PowerPoint presentation, "How to Overcome Change Initiative Objections and Cultural Road Blocks."

To open the
"Forward to" form:

 

Knowledge and implementation know-how you'll not find in the
books at Amazon.com... neither in the APICS Library 
nor the Harvard Business School Press.  

Business Basics, LLC
6003 Dassia Way, Oceanside, CA 92056
West Coast: 760-945-5596 

© 2000-2014 Business Basics, LLC