Gradually, through trial and error in dozens of workshops in a wide range of companies and at the University of Michigan, they discovered the best way to teach mapping to groups of managers, engineers, and production associates.
Indeed, the insights gained from these workshops made it possible for them to write the Learning to See workbook in a particularly clear style.
In Training to See they pass along their accumulated knowledge of how you can teach groups of employees, and eventually your entire operating team, the fundamental principles of lean thinking through the lens of Value Stream Mapping. Mike and John provide tips on how to set up and conduct effective Value Stream Mapping workshops at your own facility. Their Training to See workshop combines classroom instruction with practical on-the-floor mapping exercises using your own product families as examples. The instructor's manual includes easy to follow instructions with icons that highlight exactly what to Say, Do, Write/Draw and Ask throughout the course.
The workshop begins with a short video introduction by Jim Womack discussing the history and evolution of lean principles. The instructor then presents key lean concepts including the identification of product families, the nature of waste, the need for continuous flow wherever possible, the importance of smooth pull facilitated by heijunka, and the critical role of management in striving for perfection along each value stream.
Each member of the class follows along with their participant guide as the instructor demonstrates how to draw a detailed map of the current state using a simple manufacturing example. Armed with a basic understanding of mapping, participants form teams and go out to the gemba, the workplace, to map the current state for one or more of their own product families. They then return to the classroom to present and discuss their maps with the rest of the class.
Next, the instructor explains what makes a value stream lean, and once again uses a simple example to lead the class in mapping a future state. The students then go back out to the gemba to map the future state for the product family they have selected. After another debriefing session, participants develop the implementation plan they will follow to achieve immediate and sustainable results. The workshop concludes with some final words of encouragement from Jim Womack.
Each Training to See kit contains:
<ul>
<li>A facilitator's guide with step-by-step instructions on how to teach the material and tips from Mike and John on particularly effective techniques</li>
<li>An opening and closing video (VHS) featuring Jim Womack discussing the history of lean, the critical importance of value stream mapping, and the opportunity for each participant to actually make a difference in the future success of their company</li>
<li>A copy of Lean Thinking by Jim and Dan Jones</li>
<li>21 participant guides</li>
<li>A set of transparencies with all of the visuals needed for the course</li>
<li>A CD-ROM with PowerPoint slides of all the overheads</li>
<li>A laminated wall chart tracking the progress of the class</li>
<li>A copy of Mike and John's Learning to See
</li>
<li>Recognition certificates for each participant</li>
<li>A sturdy and attractive carrying case</li>
</ul>
Every company that is serious about becoming lean will need to teach its entire workforce and then its suppliers how to see and how to eliminate waste in every value stream. Training to See is the essential teaching tool for achieving a successful lean transformation.

VSM Participant Guide for Training to See: A Value Stream Mapping Workshop

Business & Money

Shook, John

ROTHER,MIKE

Finance

Lean Enterprise Institute, Inc.

We've developed the contents of this participant guide to enhance learning. The structure of the modules in the guide matches the learning structure used in the Training to See Kit. The page design includes space for note taking, working on an operator balance chart, and drawing both current and future state value-stream maps along with the instructor.Modules begin with a page showing the learning framework of where students are in the course content, what they’ve covered, and what comes next. Each section ends with a short quiz to check and reinforce understanding.20 Participant Guides are included in each Training to See Kit, giving you everything you need to run value-stream mapping workshops. The guides are also sold individually for additional training sessions.

Value-Stream Mapping Workshop Participant Guide

Management & Leadership

Ideally, we would all learn how to implement a lean transformation by going to the gemba, where a skilled sensei would stand by our side, helping us observe and understand how our entire team defines success -- at planning, executing, and evolving our strategy. This seasoned veteran would help us reflect on our experience, and work with the team on generating new knowledge and continuous improvement. Unfortunately, senseis are in short supply today, and there aren't enough models of transformation that provide an insider's view of how lean initiatives really work. Where can we find guidance in leading a team through a lean transformation? The Lean Enterprise Institute book, The Gold Mine: A Novel of Lean Transformation, sheds light on how lean managers can address the many challenges to rolling out systematic change. This companion product, A Leader's Study Guide to The Gold Mine, is designed to help lean leaders support their teams as they work through the process of learning lean from the ground up. A growing number of management teams in the lean community have been inviting members to read The Gold Mine and apply its insights and information to their own transformation. The Lean Enterprise Institute has developed this reader's guide to make these discussions even richer. With its chapter summaries, suggested discussion points, and recommended resources, perhaps the guide can even provide just a little sensei wisdom as well.

A Leader's Study Guide to The Gold Mine

Tom Ehrenfeld

Reference

Managing on Purpose: Using hoshin kanri to develop strategy, align teams, grow leaders, and innovate your enterprise

Mark Reich

Mapping to See: Value-Stream Improvement for the Office and Services is a complete training solution, designed to teach proven VSI methods to office and service environments in companies of all sizes. The kit is based on the value stream improvement project experience of some of the most seasoned veterans working in lean today. The process and tools they share have been developed over hundreds of projects in virtually every type of industry. The Mapping to See kit is based on the same easy-to-use format as our successful Training To See kit, and provides even more help for both the new and experienced trainer/facilitator. The kit includes everything you need to: Select and scope a value-stream improvement (VSI) project that really matters to the business. Conduct a training workshop for all of the key people in the VSI project that produces a current-state map that clearly identifies problems in your process flow, a vision of the future state that is reviewed by leadership, and a detailed action plan with a management commitment to support the recommended value stream changes. Produce a 60- to 90-day implementation plan that creates meaningful and sustained business results. The MTS kit helps you to train people in all parts of a VSI project, including VSM and more. The kit is based on the principle that VSM makes the greatest impact when it helps real people dramatically improve real value streams that have a real impact on the heart of their business.

Mapping to See: Value-Stream Improvement Workshop

John Shook, Beau Keyte, Jim Luckman, et al.

Michael Ballé and his father Freddy have written three novels that form a trilogy of lean discovery. This companion study guide will help you and your team explore together the novels and their lean principles, tools, and insights to more deeply understand and adopt kaizen spirit into your daily work. Lean is very much a journey of learning-we hope this guide helps you navigate yours. The guide is designed to work through the books one chapter at a time. The material is structured to support a regular cadence of team discussions. Each chapter section contains: 1. A chapter summary. 2. Author explanations of the significance of each chapter and how specific tools embody specific lean principles. 3. Key ideas contained in the chapter. 4. Reflection questions to guide your conversations.

The Gold Mine Trilogy Study Guide

Ballé, Michael

Follow the Learner: The Lean Bakery is a quick, entertaining story about a successful bakery and cafe business in Barcelona, Spain. They supply over 100 cafés (shops) daily with freshly baked bread and products, from a small 7,000 sq. ft. factory. The owner and author, Juan Antonio Tena faced a capacity crisis in 2005. He thought he needed more factory space and freezers to grow from 6 to 9 shops. But this expansion project was going to be very expensive and would put his entire business at risk. He picked up a copy of Lean Thinking by Jim Womack at the airport and read it on vacation. He returned home to Barcelona, ready to experiment with removing waste instead of expanding. He has been applying lean thinking ever since with remarkable results. His wife and co-author, Emi Castro is in charge of the shops. They introduced lean thinking to the shops in 2010. They have created a simple yet powerful pull and supply system that allows a café to serve thousands of customers daily with a storage space the size of a bedroom closet. They also studied and reconfigured the roles of café staff into A + B work. The majority of shops can serve all their customers and maintain the space with just 2 workers. The authors believe that running experiments to remove waste is the best way to get closer to your customers. The book includes an example of their approach to lean problem solving-complete with worksheets-and an invitation to run your own experiments.

Follow the Learner: The Lean Bakery

Juan Antonio Tena

Emi Castro

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Books by Lean Enterprise Institute, Inc.