Why Most Lean
Manufacturing-Operations Excellence Initiatives Fail to
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-Operations Excellence,
Do-it-Yourself, Team Training Program
Part No. 1: Showtime! Lean Manufacturing Simulation Game
What I hear... I forget,
What I see... I remember,
What I do ... I understand
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.
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
Your Lean Manufacturing simulation game is
initiated by hands-on
participationby team members that will setup MRP and
LEAN production factory simulations for the purpose of demonstrating
and comparing the effectiveness of two production
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."
A Customer's Testimonial:
We have been using Bill Gaw's ShowTime!
Lean Manufacturing Simulation Game
for well over five years and have used it to introduce over 40
team members to Lean Manufacturing concepts. It allows the trainees
to experience the difference between the MRP "push" system vs. the
Lean "pull" system. Classroom training has its' place, but this
simulation really hammers home the difference between the two
different scenarios. Experiencing the difference is much more
powerful than simply learning about it.
Bill has also been very responsive when we
have had questions or needed additional supplies or insight. I would
,without reservation, recommend Showtime! to anyone searching for a
simulation to demonstrate the benefits of Lean Manufacturing.
Tom Doyle, Quality Assurance and
National Optronics email@example.com
Part No. 2:
"The 10-Basics of Best-in-Class,
Why Do Most Lean Operational Excellence Initiatives
Fail to Meet Expectations?
A while back, the Aberdeen Group, published a benchmark
report the found that only 20% of the 300 manufacturers that participate in the study
could be considered
best-in-class,. The report went on to say:
Companies that have achieved lean operational excellence share this important characteristic:
"Dedication to basics such as streamlining processes, creating
a well ordered work environment, and ongoing continuous improvement programs (Kaizen)."
As the saying goes... it's
the BASICS, friend!
We realize the
word "BASICS" is not very sexy. But it is a very
important thing to understand.
The fact is, best-in-class, lean operational excellence basics... the things that serve as a solid foundation for
growing and enduring success have not changed since before I was born...
and won't change after you're dust.
It's tempting to think
that they do... that the introduction of computerized systems like
Enterprise Resource Planning (ERP), Customer Relations Management, (CRM)
and Six Sigma can change the BASICS.
We understand the
We can only caution
Mastering lean operational excellence basics of what has worked in the past establishes
needed to successfully implement and optimize the change initiatives of
today and tomorrow.
Best of all, work becomes fun again.
of Best-in-Class, Lean Operational Excellence"
Many historic, recurring day-to-day problems (perhaps the same
problems that plague your operation) can be permanently eliminated by a
tenacious execution of the 10-Basics of Best-in-Class, Lean Operational Excellence.
for optimizing and sustaining growth and profits *
for increasing speed
for improving customer responsiveness *
for transforming a vision into reality *
for exceeding goals and expectations *
for creating a fun working environment *
for individual growth and earnings *
for creating a winning culture.
The e-Library is a grouping of 10 e-Tutorials that are
delivered via Internet download and can be installed on all Internet
devices and a company's Intranet. You'll also be able to print hard
copies and create an effective reference binder for your company
trainer. (Training package also includes a "Train-the-Trainer" Manual
and "How to Overcome
Objections and Road-blocks" presentation.)
For more than 15 years, our 1900 plus customers and
15,000 plus newsletter subscribers have looked to Business Basics as
a trusted developer of "Back-to-Basics" training materials.
Knowledge and implementation know-how that's helping individuals and companies
reach their full growth and earning potentials
Our PowerPoint-Plus e-Tutorials include powerful
PowerPoint charts and graphics, "plus" annotated note pages with "slide commentary" and "lessons learned"
by a "been there, done that professional. A value added, learning experience on "how to"
plan, implement and optimize a lean operational excellence transformation.
Our customers study the e-Tutorial content, print relevant sections, and highlight passages that are important
for understanding and executing change initiatives. The resultant blueprint is used for
their teams to achievements beyond expectations.
One of the keys to
success is having a great
coach. Whether you're in the
trenches or working your way up the
corporate ladder, the
experience of someone who's
"been there, done that" can
be invaluable. Throughout
his knowledge transfer Bill Gaw
provides expert know-how,
support, empathy, respect
and most important, the
Our customer list speaks for itself. These companies are serious, as we know you are, about optimizing company results and improving their bottom line. To review a partial list of customers using
Bill Gaw's’ Power-Point-Plus
training materials in their pursuit of Best-in-Class, performance, simply click on
is an example of a PowerPoint-Plus
graphic with its relevant 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.
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 separates the exceptional
leaders from the pack. To develop the ability to
apply the “test of reasonableness,” a
leader must first become an expert at
demonstrate the How-To.
Operational Excellence Training
the "how to" that really counts!
Gaw's training is focused on the "how to." Unlike
other training materials 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."
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 newsletters because they are informative, educational and right on the
Phil Andrews,Business Development, Project Manager
“Bill's experience and the
resources he provides are first rate and of great practical
value for both the experienced manager wishing to push
improvement in their business as well as people at the
beginning of their careers who need to understand the basics
of making businesses lean and effective”
Quentin Kopp, a LinkedIn.com recommendation
Do-it-Yourself, Team Training Program
Featuring Bill Gaw's Manufacturing
Simulation Game and his
"10-Basics of Lean
To help you realize the full benefits
Manufacturing-Opera-tions Excellence, Do-it-Yourself, Team Training Program
it includes all the below training materials:
2. 10-Best Practices
of Lean Operational Excellence
will never achieve their lean operational excellence expectations as
long as business leaders continue to talk about value-added supplier
partnerships, while continuing to deal with their suppliers as
No. 4: Information
MRPII/ERP expectations will not be achieved when day-to-day
production and manufacturing/supply chain control systems are
driven by inaccurate, untimely and uncontrolled data and/or
No. 5: Value
Stream Mapping e-Tutorial
Analysis of the processes which the maps
represent can help you increase customer satisfaction by identifying
actions to reduce process cycle time, decrease defects, reduce
costs, establish customer-driven process performance measures,
reduce non-value-added steps, and increase productivity are a few.
No. 6: Kaizen
Price Pritchett puts it this way," Without Kaizen,
you and your employer will gradually lose ground. Eventually, you’ll
be “out of business,” because the competition never stands still."
No. 7: Performance Managemente-Tutorial -
Financial numbers may tell us who's winning the war, but it takes a motivational balanced scorecard measurement system to win all the battles along the way. Remember, without data
management is just another opinion.
No. 8: Cycle Time Management e-Tutorial
If your business teams can handle only one strategic
initiative at a time, then let it be the implementation of a
cycle time reduction program. There just isn’t any other more
important program in our pursuit of profits.
No. 8: Sequential Production e-Tutorial
Effective shop floor control has proven elusive as we have upgraded
our manufacturing control system from MRP to MRPII and then
to ERP. To capture control of shop floor activities, we need to
stop beating a “dead horse” and implement the Sequential
Production Process. The winners are!.
No. 10: Production Linearity e-Tutorial
Companies will never achieve their full growth and profit potential
if they produce more than 25% of their monthly shipment plan in the
last week of the month or more than 33% of their quarterly shipment
plan in the last month of the quarter. As companies struggle to
remain competitive, one of the strategies by which gains in speed,
quality and costs can be achieved is to pursue and achieve linear
>>>>> PLUS <<<<<
Bonus No. 1: Thinking Outside-the-Box
(Value $96.00)Creative thinking skills are
required by everybody. Each and everyone needs to continuously
challenge and expand their ways of thinking to enhance personal and
Bonus No. 1: How to Overcome
Objections and Roadblocks A PowerPoint-Plus
Bonus No. 1: Train the
Should you decide to use your .ppt tutorials for
team member training, we include a hard copy of an effective training
methodology... a vital train-the-trainer resource.
Bonus No. 1:
Quality System Toolbox (Value $96.00) Provides an interactive
ISO checklist to evaluate current quality system status plus policy and
procedure templates to assist in the system documentation effort.
A $1786.00 value... discounted 50% for a Special Price of only: $893.00
A Special Offer
for Website Visitors
Program today at a special price of only $893.00.
That's a $893.00
than the price
Mr. Gaw's game
like having a
through his Lean
you'll have all
a memory of
Do-it-Yourself, Team Training Program
Our Guarantee Says it all
we will never consider your
purchase binding until you
have used your
Lean Manufacturing-Operations Excellence, 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
will work for
you that if you aren't
completely satisfied for any
reason at any time, simply
return your simulation game
for an immediate refund of
your purchase price. You simply can't lose.
ORDER NOW BONUS
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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
To order by
If you place your
order via our secure
handling are free.
We'll send confirmation by email and ship your
Lean Manufacturing Simulation Game via USPS Priority Mail
and it should arrive in 3-4 days (domestic shipments). The
10-Basics of Lean Operational
Excellence courses and bonuses
will be delivered via Internet download file and will be
sent within 24 hours.
To place your order, simply click on the blue bar below the
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The Lean Manufacturing-Operations Excellence,
DIY-Team Training Program
To order by phone: call us at 760-212-6048.
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The Ball is
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
To open the "Forward to" form:
Lean Manufacturing-Operations Excellence Training
Management Development you'll not find in the
at Amazon.com... neither in the
APICS Library nor the HBS Press.
Business Basics, LLC
6003 Dassia Way, Oceanside, CA 92056
West Coast: 760-212-6048