Lean Manufacturing
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Bill Gaw

Who is Bill Gaw?

And why should we
listen to him?


lean manufacturing principles and techniques training

The Lean Manufacturing, PowerPoint-Plus,
Do-it-Yourself, Team Training Program
 (Includes Train-the-Trainer Manual)

lean manufacturing game
 


Article: Dynamics of Change 2 of 7

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Why Most Lean Manufacturing Initiatives Fail to Meet Expectations

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 techniques and practices for identifying and eliminating their root causes.

The Lean Manufacturing, PowerPoint-Plus,
Do-it-Yourself, Team Training Program

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

Part No. 1: The Lean Manufacturing Simulation Game

     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. It communicates the need, gains company-wide commitment and relevant support of their lean manufacturing transformation.

Your Lean Manufacturing simulation game is initiated by hands-on participation by team members that will setup MRP and LEAN  production factory simulations for the purpose of demonstrating and comparing the effectiveness of two production methods.

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


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 and when the lean manufacturing buy-in occurs.

 

The Lean Manufacturing Simulation Game will clearly demonstrate the complexity of shop floor control under a standard MRP (Push) production system. The opening of shop orders, picking of parts, building of assemblies and the final product production process are carried out in real-time.

The Lean Manufacturing Simulation Game is a demonstration of how sequential production and point-of-use inventory 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 forum drive home the lean 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.


 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
 

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

A while back, the Aberdeen Group, published their “Lean Benchmark Report.” Of close to 300 manufacturers that participate in this study, 90% reported that they are committed to Lean. However, further analysis found that less than 20% of these companies can be considered best-in-class. The report went on to say: "Companies that have achieved operational excellence through the deployment of a lean strategy share this important characteristic:

"Dedication to basics such as streamlining processes, creating a well ordered work environment, and ongoing continuous improvement programs (Kaizen)."
 

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 Basics Lean Manufacturing.

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.   
 


  Kaizen Based Lean Manufacturing (KBLM)

"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

DIY, "Make-a-Difference," Lean Manufacturing Team Training

For more than 13 years, our 1700 plus Customers and 16,000 plus MMBP Bulletin Subscribers have looked to Bill Gaw as a trusted developer of Power-Point-Plus tutorials and training programs. Team 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 reference documents.

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 self-directed work teams in their pursuit of best-in-class manufacturing. 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 includes a "Train-the-Trainer" Manual should your training leader needs some help in preparing and 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
 

The Lean Manufacturing, PowerPoint-Plus,
Do-it-Yourself, Team Training Program

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, PowerPoint-Plus, Do-it-Yourself, Team Training Program, it includes all the below training materials:

1. Lean Manufacturing Simulation Game

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

3. CD - Video, "Push vs. Pull"- The 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.

4. 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.

5. 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.

6. 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.

7. 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.

 8. 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.

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

10. CD - Overcoming Obstacles and Roadblocks


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, PowerPoint-Plus, Do-it-Yourself, Team Training Program affordable so that it can fit easily within your company's training budget. We want you and your company to have the best training program 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, Video - "Push vs. Pull" (Priceless)

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

5.  CD, Thinking Outside-the-Box (Price: $67.00)

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

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

8.  CD, Quality System Toolbox (Bonus)

9.  CD, Train the Trainer Manual (Bonus)

10.CD, Overcoming Objections and Roadblocks (Bonus)

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


 The Lean Manufacturing DIY Training Program

$596.00

Order your Lean Manufacturing DIY Training Program 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.
 

The Lean Manufacturing, PowerPoint-Plus,
Do-it-Yourself, Team Training Program

The Lean Manufacturing Program to help you:

*  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, workshops and consulting services that have helped improve the spirit and performance of individuals, teams, and companies.

Our Guarantee Says it all

We are so sure that your Lean Manufacturing, PowerPoint-Plus, Do-it-Yourself, Team Training Program will have the impact you desire that you can order entirely at our risk. The Lean Manufacturing DIY Training Program 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  your Lean Manufacturing, PowerPoint-Plus, Do-it-Yourself, Team Training Program 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 Training Program 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 program and helping yourself and your company achieve their full growth and earnings potential.

 

 
 ORDER NOW BONUS No. 3

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, PowerPoint-Plus, Do-it-Yourself, Team Training Program via USPS priority mail. We'll send confirmation by email and you'll have your training program 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 Program:

 

To order by phone: call us at 760-212-6048.

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


The Ball is in Your Court

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"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.  

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