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Plan and Conduct Training


Identify the training needs for every staff member associated with the line, from Operators to Managers. Create a training matrix to document the current state of process and product knowledge as well as knowledge of Lean tools. Develop a training plan to precede the line’s physical deployment.

Review All Work Documentation

Gather all documentation related to work content and steps in the Line Design: Workstation Definitions, Standard Work Definitions, and any available Graphic Work Instructions.

Define Skills by Process/Station

Define the skills required for every workstation based on the available information. For every process and workstation in the Mixed Model line, detail and document the skills required.

Assess Current Skill Levels

Assess the skill levels of all operators in the target area required to support the new line design. Develop a skills matrix or a certification board documenting skills by person and workstation. Note and document gaps.

Conduct Basic Overview Training

Conduct a overview of the basics of Flow Manufacturing and basic lean tools for all operators, line leaders, and supervisors. Emphasize benefits of the Lean workplace. Conduct handson, role-playing exercises, and live simulations for flexing, IPKs, Kanban replenishment and all other relevant principles.

Train to the Workstation

Train the Operators for workstation-specific work. Materials include SWDs, GWIs, Workstation Definitions, material presentation and replenishment, key quality checkpoints. Emphasize Check-do-check and Flexing.

Certify Operators

Observe the target area Operators with the goal of certifying the group that will bring live the Mixed Model line. Supervisors and area leaders support and coach where required, to certify that work is being with quality within Takt time. Record on the Certification Board.

Sustain Skill Levels

Determine interval for renewing skills: six to twelve months. Include dates on Certification Board to schedule refresher or re-certification.