Training "Lean: the keys to Good Lean and traps of Bad Lean"

What is "Good Lean" and what is "Bad Lean"?

Nearly everyone is “already doing Lean” and, in the vast majority of cases, the results are disappointing, both financially and in terms of the adoption of the different elements, from the tools and principles to the “philosophy” or Lean culture. Yet the company that "invented" Lean – Toyota Motor Company – continues to outperform its competitors all over the world. For instance, in France where Marris Consulting is based, the Toyota Motor Manufacturing France (TMMF) car assembly plant continues to be profitable and continues to grow in sales and in the number of its employees thereby demonstrating the power of “Good Lean”.

No other car manufacturer can do this. How does Toyota obtain results that all their competitors claim are impossible?

To understand the key success factors of Toyota, Marris Consulting has the honour of welcoming Reynald Debaut-Henocque, ex-Vice President of Manufacturing of Toyota Motor Manufacturing France to co-host these training sessions. He has experienced first-hand the development of Toyota’s manufacturing in France since 1999. He will explain the Toyota way or “Good Lean” during two thirds of this training. Philip Marris will complete the picture by presenting the “Bad Lean” practices that he has observed based on his over 30 years experience in over 270 companies all over the world and in all kinds of industries. He will also explain how to adapt Toyota's solutions to other non-automotive industries.

This is “advanced” Lean training, we do not present the basics of the Lean tools (5S, 5 whys, etc.). The topics covered include: partnership with suppliers; Lean product development / Lean Engineering; Manufacturing management; Quality management; Standardized work; Visual management; the essential growth in turnover ...

The goal of this training is to help organisations improve their performance by understanding the keys to “Good Lean” and avoiding the pitfalls of “Bad Lean” so that they can adjust, build or rebuild their Lean efforts and get closer to the results obtained by Toyota whatever their business.

How to launch, revive or accelerate your Lean initiative?

Teaser of the training course

Trainers

 
Reynald Debaut-Henocque

From 1981 to 1999, he forged a career as Quality Director for automotive equipment manufacturers accompanying the revolution in quality procedures for OEMs. His experience spans both Europe and North-America. In 1993, he set up the European continuous improvement system of the BTR group.

In 1999, he joined the Toyota group as Quality Director and succeeded in obtaining the 1^st Warranty Award when the Toyota Yaris “made in France” was launched. He broadened his horizons by going on to occupy the positions of Production Director and then Supply Chain Director.  He therefore was a key actor in the success of an industrial site which rose to the challenge of producing profitable B segment vehicles (small cars) in France; more than 3 million cars in 20 years. As Vice-President of Production, he prepared the ramp-up of the French factory to produce 3 million vehicles in the next 10 years.

Philip Marris

Philip Marris started his journey in 1986 when he joined Creative Output and collaborated with Eliyahu Goldratt, inventor of Theory of Constraints and author of the world bestseller "The Goal". In 1994, Philip in turn wrote a book on OCD, in French, to explain how to implement the ideas of the novel "The goal".

He is recognized as an expert in Lean and generally combines Lean (in Production / Engineering / Management) with TOC.

He founded Marris Consulting, based in Paris, in 2005. Half of the company's activity is located abroad, in Europe or in the rest of the world. He is bilingual and bi-cultural French / English. Very active in the "TOC" community, he has implemented The Theory of Constraints more than 270 times in more than 30 countries. Its customers include: Air France, ArcelorMittal, Ariane Group, Embraer, GSK, Ipsen, Louis Vuitton, McDonald's, Procter & Gamble, Qiagen, Safran, Salzgitter-Mannesmann, Siemens, SKF, Thales and Zodiac Aerospace.

Content

• Introduction

• The good Lean in the DNA

• The vision and the role of management  

• Toyota's 5 fundamental values

• Manufacturing management
• Quality management

• Lean Engineering

• Partnership with suppliers

• Standardized work

• Visual management

• The essential growth in turnover
• Conclusion

Extracts of the training

Are you wondering what you will learn new about Lean in this training? Discover some extracts from the complete training below:

Good Lean: We will detail how TMMF (intensively) trains their employees.

Bad Lean: Training budgets are the first to be cut in the event of difficulty.

Did you know that the Toyota plant in Onnaing in France is the most compact of Toyota's factories?

Supplier partnership extract:

• «Suppliers have more to fear from Toyota operations than purchasing.», «A near-perfect level of quality is expected, less than 30 PPM. »,

• The partnership with suppliers "à la Toyota" is almost never copied. Why!?

• «At the inauguration of TMMF some suppliers were historical suppliers to Toyota. During the first 10 years some of these suppliers disappointed and were replaced by others. But now with the launch of the 4th generation of the Yaris in 2020, there has been no noticeable change of suppliers. There are no longer any blacklisted suppliers. »

Lean Engineering extract:

• « Developing Lean Inside products»

• «Developed by Toyota and for Toyota without design outsourcing »

Download a training extract

Target public?

Sponsors, leaders or actors of transformation projects wishing to initiate or boost their Lean deployment in their company.

It is mainly aimed at manufacturing or process industries, for both repetitive and non-repetitive productions.

Service industry environments are not addressed specifically even if Lean is of course also pertinent.

Prerequisites

Have some knowledge of the tools and basic principles of Lean manufacturing which will not be detailed in this training. Examples: what is 5S, 5 Whys, SMED ...

To learn more about Toyota's Lean

Toyota key success factors only available in French