Here's how you can effectively train new employees in Lean Manufacturing through communication techniques.

Training new employees in Lean Manufacturing works best with clear communication and hands-on practice. • At Shrima Machines, we used visual aids alongside real-world applications. For example, we created visual guides for mold setups. This helped our operators work better and make fewer mistakes. •As a result, new team members quickly learned complex processes and helped us cut production time by 30%. The key is to make complex ideas easy to understand with real-world examples. We encouraged questions and open discussions. By showing how Lean methods helped right away, we built a team where everyone, including new hires, was excited to keep improving our work.

En las organizaciones LEAN se debe incluir en el proceso de on boarding una calificacion basica de Lean, he visto que las llaman white belt. Se les da a conocer los MUDA's, herramientas RCA y los principios basicos de lean manufacturing. Teniendo esto en mente cualquier nuevo colaborador tiene un conocimiento basico para identificar una perdida y hacer un analisis causa raiz con sus contramedidas, esto empodera a los nuevos empleados desde un inicio y los sumerges en la cultura de mejora continua.

In my experience, before delving into the specifics of Lean Manufacturing, it’s essential to engage new employees effectively from the beginning. Creating an open and welcoming environment where questions are encouraged, and every trainee feels valued is key to fostering a collaborative atmosphere. This sets a strong foundation for learning and applying Lean principles. Here’s how to achieve this: 1. Establishing an Open Environment 2. Icebreakers and Introductory Sessions 3. Fostering a Collaborative Atmosphere 4. Setting the Tone for Future Communication Engaging new employees effectively before diving into Lean Manufacturing specifics is crucial for setting the stage for success.

To effectively engage new employees in Lean Manufacturing, start by creating an open environment where their input is valued. Use icebreakers and introductory sessions to build rapport and set a positive tone for future communication. Encourage questions and ensure that everyone feels their contributions are important. By showing genuine interest in their perspectives, you foster a collaborative atmosphere that is conducive to learning and applying Lean principles.

The best concepts are the simple ones. Most do not remember more than 30% of what has been shared after a training session. So, it is important to keep it simple. Let them remember the key points, and if they need more info to apply at work, they can seek help from me or the web (even AI these days)!

Sustainment of lean requires creating a culture that embraces it. Nothing kills culture in the cradle quicker than complexity! Both lean and its sneakily complex cousin six sigma, have been written about and built upon for so many years now that they have grown tentacles of complexity and academic rigor far beyond their original intent. That is the quickest way to make them a specialty rather than a culture, which limits their power. Less is more when it comes to lean training. Keep concepts simple; concentrate training on real world problems and encourage adaptation in the use of the tools you teach (there is no one right way to do lean no matter what the book you ascribe to says). That is what generates excitement and builds culture.

In my experience, lean Manufacturing can indeed appear complex, especially to newcomers. However, effective communication can demystify these principles and make them more accessible. By breaking down concepts into simple, digestible pieces and using relatable examples, you can ease the learning process and ensure that the principles of Lean are understood and applied effectively. Here’s how to communicate Lean Manufacturing straightforwardly and engagingly: 1. Breaking Down Lean Manufacturing Concepts 2. Simplifying the 5S Methodology 3. Making Lean Principles Accessible 4. Example of Simplifying Lean Concepts: The 5S Game 5. Continuous Improvement and Feedback

In my experience, humans are inherently visual learners, and leveraging visual aids can significantly improve the comprehension and retention of Lean Manufacturing principles. By using diagrams, flowcharts, and other visual tools, you can represent processes and ideas in a way that is easier to understand and remember. Visual aids serve as valuable reference points that new employees can easily recall, helping them visualize the flow of work and identify areas for improvement in line with Lean practices. Here’s how to effectively integrate visual aids into Lean Manufacturing training. The Benefits of Visual Aids 1. Improved Understanding 2. Enhanced Retention 3. Quick Reference 4. And Engagement

Yes, real world examples makes much more sense to shopfloor staffs than any concepts or techniques. For example, when training on the concept of Poka Yoke, I typically like to give an example that they are exposed in daily life - e.g. the ATM machine. The flickering lights, the sequence of picking the card before the cash, and the cashless payment that becoming more common these days. Right after, I would like to then show them examples that we have on our own site. This gives them better appreciation and understanding to the idea of Poka Yoke.

Get to know your people and the problems they face on a regular basis. This provides ripe soil to grow interest in lean by your team. Understanding the major problems that are meaningful to your team allows you to teach them how lean can help to solve those problems. Once you are able to demonstrate some success on some of those problems, it is much easier to make the case for voluntary adoption of lean tools to other things. Success in lean is an exercise in voluntary adoption, not compliance to what you are being told to do. Demonstrating its power to solve the problems that are most important to your team will better open their arms (and minds :) ) to it!

I consider 3 practices for any Lean training topic. First, practice during the session; break into small groups, discuss and apply. Next, its a 'homework'; apply the key concept learned and submit for review & feedback. Extra coaching can be applied during the feedback. And lastly, have a Continuous Improvement system within your team/site; give them opportunities to further apply what they learned in Kaizen teams. The last practice is the most important, yet the most challenging to apply. Everyone is busy, but I always remind the team - 'Let's improve to reduce our work, instead of fire fight for more fire in the future.'

Let new employees lead while you guide them. Allowing new employees to implement their initiatives and leading the implementation process can fast track learnings and improve accountability. Train the trainer concept is a great model to develop employees. It promotes a two way learning growth opportunity for new employees and seasoned trainers. The outcome of it, can be improved performance or business efficiency and improved morale.