Training Catalog-India

THE TBM INSTITUTE for
OPERATIONAL
EXCELLENCE

Achieve Competitive Advantage
and Profitable Growth
LeanSigma™ Training and Development Catalog – India

Certification | Workshops | Events | Tailored Training

THE TBM INSTITUTE for
OPERATIONAL
Table of Contents EXCELLENCE

About TBM Consulting Group 2
Some of Our Global Clients 3
The TBM Institute for Operational Excellence 4
Comprehensive Training Solutions 5
Public Workshops
Leveraging LeanSigma™ Approach for Growth (LLG) 6
Lean as a Strategy for Improving Operations (LSIO) 7
LeanSigma™ Overview (LSO) 8
On-site Certification
Lean Certification Kaizen Facilitator and Lean Certification Program Leader (LC) 9–10
LeanSigma™ Green Belt (LSGB) 11
LeanSigma™ Black Belt (LSBB) 12

Client Case Studies 13–14
On-site Workshops
Creating a Continuous Improvement Office (CCIO) 15
Design for LeanSigma™ (DLS) 16
Kaizen Breakthrough Experience (KBE) 17
Kaizen Instructor Training – Business Process (KIT-BP) 18
Kaizen Instructor Training – Manufacturing Operations (KIT-MO) 19
LeanSigma™ for Process Industries (LSPI) 20
Lean Tool Kit (LTK) 21
Managing for Daily Improvement Training (MDI) 22
Sustaining Lean Results (SLR) 23
Lean as a Strategy for Improving Operations – Garment Industry (LSIOG) 24

Client Case Studies 25–26

TBM Training Team 27–28

Registration Information 29


+91.124.437.5995 | www.tbmcg.in

About TBM Consulting Group

Headquartered in the United States, with an office, consultants and trainers in India, TBM
Consulting Group is a global leader in lean operations management and business performance
improvement. In business for over 20 years, we operate on five continents, in multiple languages
and serve a broad array of industries: consumer products, food and beverage, garments, industrial
products, medical products, packaging, pharmaceuticals, railways, retail, semiconductor
manufacturing and more.

The hallmark of our work is
rapid implementation and
generating sustainable results. Our
proprietary LeanSigma™ approach
leverages lean and Six Sigma
tools and processes to create
organizational transformations
that drive flexibility, control and
responsiveness. Our process helps
you break down your barriers
to attain new levels of efficiency
and productivity, and exploit
new competitive advantages. We
typically produce 3-10X return
on investment in the form of cost
savings, working capital reduction
or revenue growth.

Unlike other consulting firms, TBM takes a holistic approach to every engagement. We work
with you to improve business performance by leveraging your investments, creatively engaging
human resources and focusing on the areas that deliver valuable business benefit. Furthermore,
we work side-by-side with your leadership team to develop a clear roadmap for improvement
that links to quantifiable business objectives. The results? An organization that is well positioned
for today’s markets, with market share gains, minimal capital investments and a competitive
advantage that is difficult to replicate.


+91.124.437.5995 | www.tbmcg.in

Insert of Our Global Clients
Some Title
Subtitle

Manufacturing Industries Served
Consumer Industrial Med Pharma Food & Beverage Transportation
Garment

Manufacturing Industries Served

Service Industries Served
Retail Insurance Healthcare Financial Serv. Government


+91.124.437.5995 | www.tbmcg.in

The TBM Institute for Operational Excellence

Certification • Workshops • Events • Tailored Training
The TBM Institute for Operational Excellence is the training arm of TBM Consulting Group, Inc., the leader
in operations management and business process improvement. We are thought leaders with deep experience
using the LeanSigma™ approach to achieve competitive advantage and profitable growth. Our mission is to
provide you with the education, framework and structure to execute your critical business objectives. We help
you to build awareness, commitment, skills and enthusiasm for your business transformation across all levels
of the organization.

We offer a broad range of hands-on, experiential training and certification courses that will give your business
teams a thorough understanding of LeanSigma™ tools and we provide the coaching to launch or reinvigorate your
continuous improvement program. The more we understand your specific business challenges, the better we can
suggest, develop or deliver a training program that meets the needs of leadership, management, supervisors, and
associates throughout the organization—in both manufacturing and supporting office functions.

We offer the following comprehensive suite of training solutions:
• A complete curriculum of lean workshops delivered at your facility on the shop floor or in
administrative functional areas such as product development, accounting, sales and marketing
or customer service
• Train-the-trainer, mentoring, and certification programs
• Tailored lean training program development and delivery
• Cultural assessment and leadership development
• Content development and material licensing

What’s different about The TBM Institute for Operational Excellence?
• Alignment of training delivery with business results
• All trainers experienced with hands-on lean implementations
• Trainers are from India and other worldwide locations
• Deep lean knowledge rooted in the fundamentals of the Toyota Production System
• Flexible approach and content for your lean training program
• Comprehensive programs for train-the-trainer and program management

We can help you create the right training program for lean practitioners, mid-level managers, or executives
including awareness training, leadership and culture training, skill development, or certification.


+91.124.437.5995 | www.tbmcg.in

Comprehensive Training Solutions

The TBM Institute for Operational Excellence offers a broad range of training options to advance
critical knowledge required to support and sustain results of your lean transformation efforts.

Public Workshops
Today, we are pleased to offer three awareness workshops, that are open to anyone who wishes to
be introduced to the concepts of LeanSigma™. This training is designed to help associates at various
levels understand the purpose of embarking on a lean journey and explain their role in supporting
the effort; provide insight into the changes that lie ahead; and show how this supports a strategy for
driving profitable growth.

On-Site Certification
Develop skill mastery through our experiential, hands-on courses for Lean Certification – Kaizen
Facilitator or Program Leader, LeanSigma™ Green Belt or LeanSigma™ Black Belt. These courses are
appropriate for organizations who wish to create in-house experts capable of supporting and driving
operational excellence program objectives. All certification courses are available for on-site delivery at
your facility.

On-Site Workshops
Choose from a broad range of training workshops to advance critical knowledge required to support
your lean transformation efforts. All workshops are available for on-site delivery at your facility.
If you require a more tailored workshop specific to the needs of your organization, please contact
us to discuss in more detail.

Conferences and Events
Every year, the Institute hosts various conferences and events that encourage benchmarking,
networking and sharing of experiential learning. Please visit www.tbmcg.in/conferences
for more information.

Tailored Training
Customers rely on The TBM Institute for a tailored
lean training program that meets their requirements
for developing resources capable of delivering
growth, profitability, flexibility and responsiveness.
Organizations with heavy Six Sigma focus often
seek our assistance integrating a lean perspective and
transitioning continuous improvement activities
toward customer-facing enhancements that drive
responsiveness and flexibility and, most importantly,
support growth initiatives.


+91.124.437.5995 | www.tbmcg.in

Leveraging LeanSigma™ Approach for Growth
The Executive’s Guide for Enterprise-Wide Business Transformation

PUBLIC WORKSHOP
1-DAY WORKSHOP
FOR SENIOR
EXECUTIVES

An interactive one-day workshop for senior executives
who wish to create a clear, concise and compelling
vision, and a leadership roadmap for business
Agenda
transformation. This workshop focuses on using
the powerful and proven tools of the LeanSigma™ Morning
approach, the Kaizen Breakthrough methodology, › ean business system overview
L
with case studies
and Value Innovation to create unique competitive
› How to build a foundation for success
advantages and a high-performance culture for › Creating a compelling vision
exceptional growth in sales and earnings. › Leadership roles and responsibilities
› Strategy/Policy Deployment
Ideal Attendees › High-performance culture

• Chief Executive Officers
Afternoon
• Chief Financial Officers
› ethodology and process for
M
• Chief Operating Officers driving rapid change
• Presidents › Lean production system overview
• Vice Presidents › ow to leverage LeanSigma™ approach
H
• Directors as a strategy for long-term growth
• Division Heads and sustainable improvement
› reating a customer-facing approach
C
Key Learning supported by innovation and rapid
product development
• Overview of lean business system evolution, its history, › How to get started
success stories, mission, and infrastructure for success.
• Key principles, methodologies and drivers of a long-term
LeanSigma™ business transformation for growth with case
studies, simulations and discussions. “ BM’s expertise and support in the
T
• A process for creating change based on a proven methodology implementation and sustainment of the
for strategy deployment, metrics alignment, visibility lean journey are unparalleled in the
and accountability. industry. They can transform any business
• Insights into the role of senior management in leading a into a profitable enterprise adding value
successful transformation.
to the stakeholders and society.”
Pricing Vivek Hinduja,
Chief Operating Officer
• Individual: INR: 15,000 Gokaldas Exports
• Group: Contact us to discuss on-site training for groups.


+91.124.437.5995 | www.tbmcg.in/llg
Leveraging LeanSigma™ for Growth
Public Workshop LLG

Lean as a Strategy for Improving Operations
Learn What It Takes to Launch Lean in Your Company

PUBLIC PUBLIC SEMINAR
WORKSHOP
2-day workshop
for general
senior managers

An exploration of LeanSigma™ dynamics for effecting
change. Discover what’s required to lead your own
transformation for gaining and sustaining market
leadership. Agenda
Day One
Ideal Attendees › Introduction and expectations

• General Managers › Evolution of LeanSigma™ approach

• Vice Presidents › imulation 1: Traditional Manufacturing
S
› Discussion:
• Senior Managers of Operations, Engineering, Manufacturing,
Quality, Material/Supply Chain, and Human Resources • omponents of traditional
C
manufacturing

Key Learning • rinciples of LeanSigma™ approach/
P
Kaizen breakthrough
• How to start a lean initiative and sustain momentum. › imulation 2: Application of LeanSigma™
S
• How the powerful combination of lean and Six Sigma can be principles
used to remove guesswork.
• How lean methods quickly eliminate non-value-added activities Day Two
and processes. › oundations of success: Leadership strategies
F

• Understand your company’s improvement potential – and how › Simulation 3: Value chain synchronization
you stack up versus your industry and the ideal lean company. › Leveraging LeanSigma™ approach for growth

• How to rally the organization around improvement objectives. › Getting started

• How to sequence for your improvement activities.
• How to leverage lean as a strategy for innovation,
differentiation, and growth.

Pricing
• Individual: INR: 25,000

“ ontinual improvement is a journey. Every organization,
C
however successful it may be, has grey areas which must
be tackled for further improvement. TBM provides tools,
guidance and takes us on the path of lean management,
which helps us realize hidden profits and reduce visible losses.”
Bhattacharya,
Director of Operations
WIKA India

+91.124.437.5995 | www.tbmcg.in/lsio
Lean as a Strategy for Improving Operations
Public Workshop LSIO

LeanSigma™ Overview
Insert Title
Learn how LeanSigma™ tools can benefit your business
How LeanSigma™ Tools Can Benefit Your Business
Subtitle
Learn how LeanSigma™ tools can benefit your business

PUBLIC WORKSHOP
PUBLIC WORKSHOP
3-day workshop
for mid-level
managers

During this three-day workshop, mid-level managers learn
how powerful lean tools, Design for LeanSigma™, and the
Sigma Kaizen methodology can be integrated into a high-
impact business strategy to achieve operational excellence.
Agenda

Ideal Attendees Day One
› 7 wastes
• Mid-Level Managers
› Takt, flow, pull
• Operations Managers
› Jidoka
• Line Managers
› Production smoothing
• Team Leaders
› Simulation 1: The block game
• Continuous Improvement Leaders
› Progressive 5S
• Engineers
› Kaizen Breakthrough Methodology
• Supervisors
› Standard work and process balancing
• Engineering graduates or students currently
› Assembly line principles
enrolled in engineering coursework

Key Learning Day Two
› Setup reduction
• Overview of the lean transformation roadmap.
› Total Productive Maintenance
• How to apply lean methodologies to reduce development
› Sustaining results
costs, drive customer-centric innovation, and improve speed
to market. › Value stream mapping
• How to combine lean and Six Sigma into a single, › Sigma Kaizen
coordinated initiative to realize results in less time.
• DMAIC (Define, Measure, Analyze, Improve and Control) Day Three
structured problem solving model. › Design for LeanSigma™
• Simulation and exercises are used to demonstrate and › Voice of Customer
reinforce key learning. › House of Quality
› Managed creativity
Tools Learned
› Design for Manufacturing and Assembly
• A detailed overview, for operations managers and continuous › Production Preparation
improvement professionals, who wish to understand more
› Strategy Deployment
about critical lean tools and how and when they should be
applied to improve safety, quality, delivery and costs. For › High performance culture
details about all the tools covered, visit: www.tbmcg.in/lso. › Getting started

Pricing
• Individual: INR 37,500

+91.124.437.5995 | www.tbmcg.in/lso
Public Workshop LSO

TBM Title
InsertLean Certification
Lead the
Subtitle Way

ON-SITE CERTIFICATION
Two Lean Certification Programs
Comprehensive certification training for
companies that wish to develop in-house
capabilities to accelerate their lean deployment.

TBM has created two lean certification programs for companies
that wish to develop in-house capabilities to accelerate their
lean deployment. All coursework is delivered through a blend
of online learning, on-site training, skills demonstration, and
interactive mentoring.
Registration Details
TBM Lean Certification Courses
Lean Certification – Kaizen Facilitator Kaizen Facilitator:
Learn to Support Effective Kaizen Events Pricing available upon request.

Understand essential lean tools and how they are used to drive Program Leader:
Pricing available upon request.
results. Includes self-paced online learning and three weeks of
hands-on training. Candidates will be mentored by a TBM Lean
› tudents must have access to the
S
Master and will graduate with hands-on experience and knowledge
Internet and Microsoft® applications
in the following critical areas: including Visio®, PowerPoint® and
• nowledge of lean strategies, tools, and methods which include
K Excel®. We recommend students
the fundamentals of the Toyota Production System have access to a laptop computer to
allow them to work on certification
• kills required to support effective kaizen events and conduct
S objectives during on-site events.
basic training for kaizen teams
› TBM clients who have completed

• articipation in a kaizen event on the shop floor – or in a business
P portions of the curriculum may qualify
• evelopment of a current and future value stream map for a facility
D for learning credits at the discretion of
or product family the program director.

› Please contact us if you would like

Lean Certification – Program Leader to modify the course and create a
tailored Lean Certification curriculum
Learn to Lead a Lean Deployment
for your company.
Candidates complete all coursework from the Kaizen Facilitator
course in addition to learning how to create and manage an
effective lean office and how to audit, report, and sustain results of
a lean program. Includes self-paced online learning and five weeks
of hands-on training. Candidates will be mentored by a TBM Lean
Master and will graduate with hands-on experience
and knowledge in the following additional critical areas:
• ow to create, manage, communicate, and promote an effective
H
continuous improvement office
• ow to write a project charter, develop scope, and create objectives
H
for a kaizen event
• ow to align operations metrics with financial performance
H
• ow to audit, report, and sustain results from your lean
H
deployment


+91.124.437.5995 Kaizen Facilitator - www.tbmcg.in/kf
LC
Lean Certification
Program Leader - www.tbmcg.in/pl Certification

TBM Lean Certification (continued)
Lead the Way

TBM LEAN CERTIFICATION PROGRAM CURRICULUM
Time Kaizen Program
Learning Description
Commitment Facilitator Leader

Modules include: Introduction to lean; Waste
elimination; Just-in-time principles of takt, flow and pull
Essential Lean systems; Quality and productivity improvements through
Learning– Self-paced
Jidoka; Production Smoothing, Standard Work, Standard
Online Training
and Exam*
online
learning
Operations; 5S and the visual workplace; Value Chain
Mapping, LeanSigma™ Implementation; and Roles in
3 3
a lean deployment. Candidates must pass a final exam
upon completion of all modules.

Learn how lean tools are applied to transform your
Lean Tool Kit organization to deliver improved operational results.
Workshop*
5 Days
Through the use of a factory simulation, students will be
able to apply what they have learned.
3 3
Kaizen Hands-on participation on a kaizen team at a TBM
client site. Participants are divided into teams that are
Breakthrough
Experience
5 Days
led by a TBM Lean Master. Team members are assigned
roles; the event is planned, executed and evaluated.
3 3
Train-the-trainer workshop designed to teach participants
Kaizen how to deliver TBM’s one-day lean training, an essential
component of facilitating kaizen events. Participants
Instructor
Training
4 Days
hone public speaking skills and learn how to address the
tough questions from individuals who will participate in
3 3
or be impacted by a kaizen event.
Learn the strategies, tools and skills required to set up and
administer an effective continuous improvement office.
Creating a Topics include: how to communicate and promote a
Continuous lean program, write charter statements, align operational
Improvement
Office
4 Days metrics with financial objectives, assess your lean
progression, form and manage a lean steering committee, 3
and share best practices across the organization. (We
recommend that Program Leader candidates complete this
course before taking Kaizen Instructor Training.)
Participants learn to audit, report, and sustain kaizen
Sustaining results. Concepts covered include: personality assessment
Lean Results
5 Days and how to work with different types of people, cultural
change and how to deal with resistance, performance 3
measurement, layered audits, and problem solving tools.

Mentor,
Homework, Each participant is assigned a TBM Lean Mentor
Quizzes, to guide them through the certification process.
Kaizen Event
Report-out and
Ongoing
Homework, quizzes, a kaizen report-out, and a final
exam are all part of the certification program.
3 3
Final Exam
* Candidates MUST complete the online training, Lean Tool Kit course and exam before progressing to other modules of Lean Certification.

“ y becoming proficient and certified in lean, we increased the speed, understanding, and transition
B
of lean concepts within our company. Intensive coaching and mentoring are imperative to change the
mindset through the entire organization. I rely on our TBM mentor to help make quantum leaps in
the experience. He challenges our thinking while offering perspectives on what could be better.”
Michael Gerster,
President
WIKA Instrument Corporation

+91.124.437.5995 Kaizen Facilitator - www.tbmcg.in/kf
LC
Lean Certification
Program Leader - www.tbmcg.in/pl Certification

Insert Title ™ Green Belt Certification
LeanSigma
Green Belt
Subtitle Certification with a Lean Emphasis

Hands-on, experiential training for operations
professionals who need to combine lean and
Six Sigma tools to rapidly implement high-
impact business improvements. Provides
candidates with LeanSigma™ principles, kaizen
methodology and Six Sigma statistical problem-
solving tools to create a faster approach to
identifying and correcting problems.

Three Non-Consecutive
Ideal Attendees
Week Agenda
Management and operations team members who wish to learn
and use lean and Six Sigma tools to solve business problems
Week One
using all the tools of LeanSigma™
• On-site training:
Define/Measure/Analyze phase
Key Learning
Week Two
• Three weeks of training and skill transfer • Sigma Kaizen event:
Measure/Analyze on-site
• LeanSigma™, the proven methodology which combines
lean and Six Sigma into a single, coordinated initiative Week Three
• DMAIC structured problem solving model • On-site training:
Analyze/Improve/Control phase
• Six Sigma statistical and analytical tools
Please visit www.tbmcg.in/lsgb
• Sigma Kaizen methodology and how to use it to reduce to review the detailed daily agendas.
project time from six months or more – to six weeks or less
• Leadership training on how to lead project teams within
your area of responsibility to rapidly implement high- “ is program has made a huge
Th
difference in the speed and capabilities
impact business improvement
of our new Green Belts.”
Tom Barrett,
Tools Learned Director of Continuous Improvement
Landscape Structures, Inc.
• Sigma Kaizen Methodology
• DMAIC
TBM Green Belt Training Strategy
Pricing Define Analyze/Improve
Measure/Analyze Control
• Pricing available upon request (one week classroom) (one week classroom)

LeanSigma™ Green Belt certification
is not a prerequisite for attending
LeanSigma™ Black Belt. Sigma Kaizen
Measure/Analyze
Event
(one week led by Master Black Belt)


+91.124.437.5995 | www.tbmcg.in/lsgb
LeanSigma™ Green Belt Certification
Certification LSGB

Insert Title ™ Black Belt Certification
LeanSigma
Black Belt
Subtitle Certification with a Lean Emphasis

Multi-week, experiential training for full-time,
continuous improvement and quality team
members. Teaches candidates how to lead
Sigma Kaizen events and how to use kaizen to
complete black belt projects in six weeks versus
a typical six months. The curriculum includes
value-stream analysis and Six Sigma problem-
solving tools.
Four Non-Consecutive
Week Agenda
Ideal Attendees
Full-time Continuous Improvement and Quality team members Week One
• On-site training:
Key Learning Define/Measure/Analyze phase

• Four weeks of training and skill transfer Week Two
• Sigma Kaizen event:
• LeanSigma™, the proven methodology which combines lean Measure/Analyze on-site
and Six Sigma into a single, coordinated initiative
• Tools and techniques to accurately assess Voice of the Customer Week Three
• The rationale and process for project identification and • On-site training:
Analyze/Improve/Control phase
selection
• Key lean manufacturing principles, including kaizen and value Week Four
stream analysis • On-site training:
• Advanced Six Sigma statistical problem-solving tools including Advanced LeanSigma™ skills
hypothesis testing and design of experiments
Please visit www.tbmcg.in/lsbb
• Sigma Kaizen methodology and how to use it to reduce Black to review the detailed daily agendas.
Belt project time from six months or more – to six weeks or less
• Leadership training on how to lead project teams to rapidly
implement high-impact business improvement “ ‘turbocharged’ Black Belt program,with
A
• Methods to engage executive management and to ensure more tools to achieve maximum improvement
effective governance of your LeanSigma™ initiative and quality levels in far less time.”
Frank Bailey,
Tools Learned Director, Global Continuous Improvement
Entegris, Inc.
• Voice of Customer analysis
• Value chain analysis
TBM Black Belt Training Strategy
• Sigma Kaizen Methodology
• Design of Experiments Three-week Interim Sigma Kaizen
Define
Measure/Analyze
• DMAIC Measure/Analyze Event
(one week classroom) (one week led by Master Black Belt)
Pricing
Four-week Interim
• Pricing available
upon request
Three-week Interim
Advanced Analyze/Improve
LeanSigma™ Green Belt certification LeanSigma™ Skills
Control
(one week classroom)
is not a prerequisite for attending (one week classroom)
LeanSigma™ Black Belt.


+91.124.437.5995 | www.tbmcg.in/lsbb
LeanSigma™ Black Belt Certification
Certification LSBB

Client Case Studies

Improving Productivity and Profitability
Through a LeanSigma™ Transformation

Client
Gokaldas Exports Ltd. (GEX) is India’s largest apparel exporter. It is a “one-stop shop” for the world’s most
preferred apparel brands, including major casual and sports clothing lines. In 2008, GEX had US $250
million in sales and employed 45,000 people working in 45 factories. The company has the capacity to
produce 2.5 million garments a month. The Blackstone Group recently became a partner in GEX, which
had been an entirely family-owned business since its founding in 1970.

Challenge
GEX had to improve worker productivity without adding
resources to grow profits and remain competitive in the
high-volume, low-margin global garment industry. Nike, a “ ean implementation is very
L
major client, strongly suggested that the company implement important to GEX and will be
lean process improvements, but GEX’s longtime leadership a key enabler for their future
was skeptical that lean production would work in the continued success in profitability,
garment industry. growing their top-line sales
revenue and being a world-class
Solutions quality global garment supplier.”
Reassured by TBM Consulting Group’s guarantee of
satisfaction, Executive Director Dinesh Hinduja invited Jeff Overly,
TBM into the company for an assessment and subsequent Executive Director
productivity improvement action plan based on the LeanSigma™ of The Blackstone Group
methodology. This included the training of three COOs – (U.S.A.-based private equity firm with
Ashwin Hinduja, Vivek Hinduja and Gaurav D. Hinduja all a majority investment stake in GEX)
of whom have undergone four weeks of lean training and have
received lean certification.

Results
Lean has become a key enabler for GEX and its future continued success in driving revenue, quality, and
profitability. While the retail-clothing sector was devastated by a global recession, GEX made significant
strides in on-time delivery, firstpass yield, and productivity—even growing sales by two percent in spite
of a dreadful economic downturn. Key improvements are helping to significantly improve its competitive
position within the industry: lead time, employee absenteeism and attrition.


+91.124.437.5995 | www.tbmcg.in CASE STUDY

Client Case Studies

Jump Starting a Lean Journey

Client
Several TBM clients from discrete and continuous
process manufacturing companies who are looking for “ t opened up my mind. Now
I
a way to develop internal expertise to drive their lean I can give answers based
transformation. on experience rather than
just from a book.” Gilman
believes that going through
Challenge
lean certification training is
These companies realized that they had neither one way for a company to get
the internal expertise nor the time to design, train,
people more energized in a lean
implement, and sustain a lean program on their own.
They needed in-house expertise to advocate for lean, transformation, specifically the
drive culture change, and sustain the results of their cultural change.
lean transformation. Aditi Gilman,
formerly of Appleton Papers
Solution in Roaring Spring, PA, U.S.A.

Create an internal consulting team by sending key
individuals through lean certification training. Use
those human assets to facilitate lean efforts and drive
change throughout the organization. Lean certification “ eing able to participate, talk
B
training includes a mix of intense classroom learning to the consultants and the other
and hands-on field experience shadowing a TBM participants, and seeing lean in
consultant in the field for two weeks.
action really distinguishes this
course from those that involve strict
Results classroom training like a college
Certified lean practitioners effectively become the course,” Kearns says. “The fact
recognized go-to people for lean inside their respective that the class included people from
companies. Graduates facilitate events, train others, different industries allowed me to
jump start initiatives, and save the company money. stretch [my knowledge and skills].”
Organizations get up to speed more quickly and
realize accelerated benefits in exchange for the training Todd Kearns,
investment. Lean certification helps companies gain Saint-Gobain Containers, Inc.
the most benefit for their training dollars, drives and in Dolton, IL, U.S.A.
sustains change, and translates the results into real
competitive advantage.



Insert Title
Creating a Continuous Improvement Office
Subtitle Continuous Improvement Office the Right Way
Run Your

ON-SITE WORKSHOP
SEMINAR
4-day workshop
for managers

Provides the strategies, tools and skills required to quickly
establish a highly effective continuous improvement office,
confidently chart your path of lean improvement, maintain and
build momentum and achieve dramatic, sustainable results. Agenda
Ideal Attendees
Day One
• Operations management professionals • Introductions
• General managers • Continuous improvement office organization,
• Plant managers roles and activities
• Communication and promotion
• Lean or kaizen promotion office managers and team members
Day Two
Key Learning
• Writing charter statements
• Build current and future state value chain maps • Continuous improvement benefits
• Deﬁne lean performance measures, targets and and calculating ROI
tracking strategies
Day Three
• Build and maintain momentum and enthusiasm
• Steering committee
• Drive cultural change within your organization
• Event planning and preparation
• Learn a system for targeting, planning and executing
kaizen events Day Four
• Deﬁne the standard work for leaders and managers • Lean progression rating
• Sharing best practices
Tools Learned • Review of the week
• Value chain mapping
• Continuous improvement office organization
• Cultural transformation techniques
• Performance measurement
• Lean progression rating

Pricing
• Pricing available upon request

“ is workshop was exactly what I needed
Th
to help me be an effective continuous
improvement manager.”
Les Webb,
Kaizen Promotion Office/Inside Sales,
Securitron

+91.124.437.5995 | www.tbmcg.in/ccio Creating a Continuous Improvement Office
On-site Workshop CCIO

Design for LeanSigma™
Lean Product Development and Launch

ON-SITE WORKSHOP
5-day SEMINAR
for mid-level
managers

Experience this effective approach to new product
development, production process design and implementation
within a lean framework. Learn how to consistently launch
innovative products significantly faster than your competition. Agenda

• Introductions and expectations
• Design engineers
• LeanSigma™ transformation
• Manufacturing engineers • Design for LeanSigma™ (DLS) overview
• Product and marketing managers • DLS (Phase-Gate) process and kaizen
interventions
• Operations managers
• Quality managers Day Two
• Continuous improvement managers • Voice of Customer (VOC)

• Others in the design and production process • House of Quality (HOQ)
• Design for Manufacture and Assembly (DFMA)
Key Learning
Day Three
• How to use Voice of Customer (VOC) to understand true
• Concept development and managed creativity
customer needs and translate them into critical product
• Design for Six Sigma quality tools
requirements
• Maximize quality and production ﬂexibility to easily adapt Day Four
to variations in customer demand • Lean production system
• Dramatically reduce your development costs and be consistently • Production preparation principles
ﬁrst to market with innovative, high-appeal products • Production preparation process
• Participate in a hands-on simulation and learn how to apply lean
growth tools to streamline the product development process Day Five
• Production preparation process (con’t)
Tools Learned • Exercise: “Taking it Home”
• Voice of Customer (VOC) • Conclusion and closing discussions

• House of Quality
• Managed Creativity for Concept Development “ e first product we developed with this
Th
process was in the market in one-third of
• Design for Manufacture and Assembly our normal time. The design is unlike any
• Production Preparation Process (Seven Alternatives, other comparable product with benefits
Simulation, and Process-at-a-Glance) our customers really wanted. Our biggest
competitor in that market already wants to
Pricing license it from us.”
Timothy H. Powers,
• Pricing available upon request Chairman and CEO
Hubbell Incorporated


+91.124.437.5995 | www.tbmcg.in/dls
Design for LeanSigma™
On-site Workshop DLS

Kaizen Breakthrough Experience
Insert Title
Participate in a Live Kaizen Event
Subtitle

ON-SITE WORKSHOP
5-day SEMINAR
for EXECUTIVES
AND STAFF

Experience the dramatic bottom-line improvement and
efficiency you can quickly achieve and sustain as your Kaizen
team implements lean tools on the factory floor or in a business
process support function. Agenda
Ideal Attendees
Day One
• Chief Executive Officers/Presidents, Chief Operating Officers,
• Overview of the lean production system
Vice Presidents, Directors
• Standard operations, elements,
• General Managers, Department Managers, Plant Managers and tools
• Operations and continuous improvement staff • More advanced tools depending on
• Team members from various departments including: Kaizen project chosen
Promotion Office, Quality, Materials, Human Resources, • Host company welcome presentation
Engineering • Team leaders’ briefing
• Administrative staff from various departments including:
Accounting, Marketing, Sales, Customer Service Day Two
• Host company plant tour
Key Learning
• Kaizen team activities
• Experience the key concepts, tools, and techniques used
–– Time studies
during a kaizen week
–– Workplace improvement discussions
• Participate on a dedicated kaizen team and drive immediate
improvement –– Hands-on workplace improvement

• Learn to identify waste and eliminate non-value-added activities
Day Three
• Achieve typical kaizen event results:
• Kaizen team activities
––Shopfloor Operations: Inventory reductions of 90%+, –– Continue hands-on workplace improvements
productivity increases of 25-50%, product lead times
–– Test workplace improvements
reduced from weeks to hours, elimination of safety hazards,
improved 5S scores –– Re-time cycle times

––Business Process: Backlog reductions of 90%+, cycle-times
Day Four
reduced from weeks to days, productivity increases 25-50%,
customer service levels increased to 99%+ • Kaizen team activities

• Get excited about kaizen and leave energized to apply what –– Refine improvements
you have learned –– Establish and document standard work
–– Run improvements
Tools Learned –– Re-time and establish new cycle times
• Kaizen methodology • Visual workplace management –– Prepare presentation
• Lean production system • Assembly line design
• Standard operations • Setup reduction Day Five
• Progressive 5S • Other advanced techniques • Team presentations and report-out

Pricing

+91.124.437.5995 | www.tbmcg.in/kbe
Kaizen Breakthrough Experience
On-site Workshop KBE

Insert Title
Kaizen Instructor Training – Business Process
Comprehensive Train the Trainer Program
Subtitle

ON-SITE WORKSHOP
4-day workshop
for managers

Critical kaizen instructor training that sets the foundation
for dramatic improvement and successful culture change
at the start of each business process kaizen event. Learn to
conduct day-one training of lean concepts and build team
awareness and support at the beginning of each kaizen event. Agenda

• Kaizen promotion office managers • Introductions and overview
• Continuous improvement managers • How to be an effective trainer and facilitator
• Engineers • Exercise 1: Team building
• Administrative office managers • Lean fundamentals, concepts and principles
• Five-minute presentations
Key Learning
Day Two
• Lean and kaizen training content required to build team
awareness and support at the start of each business process • Business process characteristics
kaizen event • Waste identification and elimination
• Advanced instructor presentation, training, and teaching • Exercise 2: Team building
skills – for maximum impact • 5S in the office
• Preparation techniques for business process kaizen events to • Round one presentations
ensure peak results
• In-depth familiarity with all training materials Day Three
• Interactive simulation exercises and anecdotes to reinforce • Standard operations review
key concepts • Kaizen breakthrough methodology review
• Responses and role plays for questions your instructors will • Simulation 1: Business process
commonly receive • Round two presentations
• Business process improvement tools review
Tools Learned
• Exercise 3: Team building
• “Train-the-trainer” techniques
Day Four
Pricing • Presentation videotaping
• Pricing available upon request • Business process cost savings
• Use of memory aids
Prerequisites
• Case studies
The minimum experience level required is four business
• Key learnings
process kaizen events. In order to maintain a consistent level
of experience among course attendees, we will conduct a brief
interview to determine your level of lean experience before
admittance is approved. “ onderful training! All the
W
concepts are coming together
and I’m connecting the dots.”
Stephanie Volmar,
USI


KITBP
Kaizen Instructor Training –
+91.124.437.5995 | www.tbmcg.in/kitbp Business Process

Insert Title
Kaizen Instructor Training – Manufacturing Operations
Comprehensive Train the Trainer Program
Subtitle

ON-SITE WORKSHOP
4-day workshop
for managers

Critical kaizen instructor training that sets the foundation for
dramatic improvement and successful culture change at the
start of each shop floor kaizen event. Learn to conduct day-one
training of lean concepts to build team awareness and support
at the beginning of each kaizen event.
Agenda
• Kaizen promotion office managers • Introductions and review
• Continuous improvement managers • LeanSigma™ overview
• Engineers • How to be a trainer
• Five-minute introduction presentations
Key Learning
Day Two
• Lean and kaizen training content required to build team
• Lean production system review
awareness and support at the start of each kaizen event
• Simulation 1: Flow production
• Advanced instructor presentation, training and teaching
• Standard operations review
skills – for maximum impact
• Exercise 1: Time observation
• Preparation techniques for kaizen events to ensure peak results
• Round one presentations
• In-depth familiarity with all training materials
• Interactive simulation exercises and anecdotes to reinforce Day Three
key concepts • 5S workplace organization
• Responses and role plays for questions your instructors will • Assembly review
commonly receive • Setup reduction review
• Round two presentations
Tools Learned • Exercise 2: Standard operations
• “Train-the-trainer” techniques
Day Four
Pricing • Presentations videotaping
• Total productive maintenance review
• Routing standardization review

Prerequisites • Kaizen breakthrough methodology review
• Key learnings
There will be an additional charge for access to licensed
training materials for those attendees without a signed material
licensing agreement. The minimum experience level required
is four manufacturing kaizen events. In order to maintain
a consistent level of experience among course attendees, we
will conduct a brief interview to determine your level of lean
experience before admittance is approved.


KITMO
Kaizen Instructor Training -
+91.124.437.5995 | www.tbmcg.in/kitmo Manufacturing Operations
On-site Workshop

Insert Title ™ for Process Industries
LeanSigma
Lean Immersion Workshop for Continuous Process Companies
Subtitle

ON-SITE WORKSHOP
2-day workshop
for SENIOR
managers

A senior-level overview for continuous process companies
of a proven business strategy for rapidly achieving dramatic
performance improvement with LeanSigma™ – in a fraction of
the time of traditional Six Sigma. Agenda
Ideal Attendees
Day One
• Senior management including: Chief Executive Officers,
Presidents, Chief Financial Officers, and Chief Operating • Introductions
Officers • LeanSigma™ overview
• Operations management including: General Managers, • Simulation 1
Vice Presidents or Directors of Operations, Engineering, • Creating flexibility
Continuous Improvement, Quality, Materials, Supply Chain, • Initial implementation steps
and Human Resources –– Vision
–– 5S
Key Learning
–– Overall equipment effectiveness (OEE)
• Your company’s improvement potential – and a proven
business strategy to quickly drive substantial improvement and –– Process capability
efficiency across your entire value stream –– Kaizen
• Seamlessly integrate lean and Six Sigma into a cohesive,
enterprise-wide improvement initiative Day Two

• Rapidly improve process yield with Sigma Kaizen events • Final implementation steps

• Dramatically improve process capability and equipment • Simulation 2
effectiveness without significant capital investment • Business process kaizen
• Rapidly reduce changeover and clean-out times by 75-90% • Product development
• Achieve major productivity improvement by increasing • Culture change
throughput • Continuous improvement office
• Improve process flexibility to deliver to actual customer
demand

Pricing

“ e’ve been using lean to achieve major, ongoing improvement.
W
I knew it wasn’t the answer to some of our process variation
problems, but how could I promote lean speed and action
together with slow and methodical Six Sigma? TBM has figured
out how to successfully combine the two, with lean speed and
maximum impact. This workshop put it all together for me
– it was the same type of ‘ah ha’ experience I had when first
introduced to lean.”
Rob Tracy,
Chief Operating Officer
Intek Plastics, Inc.

+91.124.437.5995 | www.tbmcg.in/lspi
LeanSigma™ for Process Industries
On-site Workshop LSPI

Lean Tool Kit Workshop
Continuous Improvement Essentials

ON-SITE WORKSHOP
5-day WORKSHOP
for EXECUTIVES
AND managers

A five-day workshop covering lean tools and how they can
be integrated as business strategies to achieve improved
operational results.
Agenda
Ideal Attendees
• Executives Day One
• Managers • Lean overview
• Supervisors • Importance of KPI’s and
• Continuous improvement leaders countermeasure system
• Engineers • How policy deployment aligns vision,
strategy, and resources
• Shop floor personnel
Day Two
Key Learning
• Factory simulation 1
• Participants are provided an overview of the lean roadmap
and the Kaizen Breakthrough Methodology • Value chain mapping
• Waste elimination
• How policy deployment drives the lean implementation
process
Day Three
• Lean tools covered include: value chain mapping, waste
• Lean production system
identification, takt time and process balancing, pull systems
and kanban, jidoka, setup reduction, total productive • Progressive 5S
maintenance, quality, Sigma Kaizen, and 5S • Standard operations
• Extending lean into the value chain • Time observation example
• Factory simulations and workshop exercises • Setup reduction
• Total productive maintenance
Tools Learned • Quality and Six Sigma
• Value chain mapping • Kanban
• Progressive 5S Day Four
• Setup reduction • Factory simulation 2
• Total productive maintenance • Design for LeanSigma™
• Kanban • Energy kaizen
• Lean value chain
Pricing
• Pricing available upon request Day Five
• Business process kaizen
• Kaizen breakthrough methodology
• Review of the week


+91.124.437.5995 | www.tbmcg.in/ltk Lean Tool Kit
On-site Workshop LTK

Managing for Daily Improvement Training
Learn How to Sustain Improvements Resulting from Your Lean Operations

ON-SITE WORKSHOP
5-day workshop
for LEADERS AND
managers

A five-day workshop, taught on the shop floor of a
leading lean company, that will provide you with
the opportunity to learn the tools and techniques
you need to implement and sustain daily continuous Agenda
improvement initiatives in your work area.
Day One
Ideal Attendees • Introductions and overview
• Lean progression and barriers to success
• Front-line supervisors, team leaders, and line facilitators
• Delta site review
• Production, process, and support group managers and
their key staff members
Day Two
• Continuous improvement or kaizen promotion
• Visual workplace
managers
• SQDC management
• Plant, division, and department managers
Day Three
Key Learning
• Critical supervisor training • Standard operations
• Leverage lean tools to identify problems and highlight • Point kaizen
resources needed
• Respond immediately to abnormalities Day Four
• Learn to apply point kaizen strategies • Solving quality problems
• Create critical performance metrics • Abnormality management
• Kaizen planning model
Tools Learned
Day Five
• Progressive 5S
• Final review
• Visual workplace techniques
• Presentation preparation
• SQDC management
• Presentation to management
• Standard operations
• Point kaizen
• Abnormality management “ anaging for Daily Improvement is
M
one of the most important aspects of a
• Kaizen planning
LeanSigma™ transformation.”
Pricing Mike Hofmann,
Executive Vice President of
• Pricing available upon request Operations for North America,
Sealy, Inc.


+91.124.437.5995 | www.tbmcg.in/mdi
Managing for Daily Improvement Training
On-site Workshop MDI

Sustaining Lean Results
Audit, Report and Sustain Kaizen Results

ON-SITE WORKSHOP
5-day workshop
for managers

A five-day workshop that gives you strategies, tools, and
skills required to preserve the returns of your continuous
improvement program.

Ideal Attendees
Agenda
• Operations management
• General managers
Day One
• Plant managers
• Cultural transformation tools
• Lean or kaizen promotion office managers, continuous
improvement leaders, and team members Day Two
• Driving cultural transformation
Key Learning • Personalysis
• Learn how to use performance measures, targets, and
tracking strategies, including how to manage and sustain Day Three
SQDC management and hour-by-hour charts • Establishing performance measures
• Learn how to audit and report the results of each kaizen • How to sustain results
project to help sustain those results • Auditing and reporting kaizen results
• Tools and techniques for creating a business control center
to keep your lean transformation organized and on track Day Four
• Creating a business control center
• Understand how to use Layered Audits, an organized group
of questions designed to examine a device or process, to • Conducting layered audits
ensure that standard work is being followed at all levels of • Understanding the A3 methodology
the organization • Problem-solving tools and methodologies
• Learn how to use the A3 Methodology to create
information flow of knowledge, ideas and experience, Day Five
which will help you to eliminate waste and solve problems • Problem-solving tools and methodologies
through a visual, easily understood process
• Understand and learn how to solve problems using the 8D
methodology. You’ll learn several tools to identify the root
cause and implement countermeasures using Poka-Yoke
• Cultural transformation tools to help establish credibility
for your improvement initiative, instill enthusiasm at all
levels of your organization, and provide essential continuity
and staying power
• Personalysis training will help you understand your
personality style and the team’s in order to take
advantage of opportunities, rather than being blocked
by interpersonal conflict

Pricing

+91.124.437.5995 | www.tbmcg.in/slr Sustaining Lean Results
On-site Workshop SLR

Lean as a Strategy for Improving Operations – Garment Industry
Leveraging Lean for Competitive Advantage in the Garment Industry

ON-SITE WORKSHOP
2-day WORKSHOP
for SENIOR
managers

A two-day workshop using discussion and interactive
simulations that demonstrate how the LeanSigma™
methodology provides a platform for effective change.
Tailored specifically for senior-level managers in the Agenda
garment industry looking to understand what it takes
to drive a lean transformation. Day One
• Introduction of lean transformation
Ideal Attendees • Case studies of successful lean companies
• General Managers and Vice Presidents or Senior Managers • Simulation 1: Traditional manufacturing
of Operations, Engineering, Manufacturing, Quality, • Introduction to lean concept:
Materials, Supply Chain, and Human Resources
–– Value chain mapping
–– The seven wastes
Key Learning
–– Valued-added versus
• How to start a lean initiative and sustain momentum non-value-added activities
• How the powerful combination of lean and Six Sigma –– 5S
can be used to remove guesswork
–– Lean production system
• How lean methods quickly eliminate non-value-added
• Simulation 2: One-piece flow, pull production,
activities and processes integrating lean, and Six Sigma
• Understand your company’s improvement potential –
and how you stack up versus your industry and the ideal Day Two
lean company • Lean production system
• How to rally the organization around improvement objectives –– Change over reduction methods
• How to sequence for your improvement activities –– Production smoothing and
mixed-model production
• How to leverage lean as a strategy for innovation,
differentiation, and growth –– Material management by using pull,
LeanSigma™ value chain
Pricing • Simulation 3: Pull system, mixed models

• Pricing available upon request • Developing a culture to sustain
your gains
• Business process kaizen
• LeanSigma™ product development
• Review of expectations
• Getting started and recommendations
for next steps


LSIOG
Lean as a Strategy for
+91.124.437.5995 | www.tbmcg.in/lsiog Improving Operations – Garment
On-site Workshop

Client Case Studies

Electricity Management Product Manufacturing

Client
Genus Power Infrastructures Ltd. manufactures electronic “ ose first projects really helped
Th
energy meters, electricity infrastructure products, hybrid everyone understand what our
microcircuits, inverters, batteries, and uninterruptible customer requirements actually
power supplies.
are. Understanding the takt
time, rate of production required
Challenge to meet customer demand,
helped us allocate people based
Genus Power’s rapid sales growth was outpacing the
company’s production capacity, which undermined its on a need basis. That concept
market position and caused it to lose some orders. Also, triggered some tremendous
its product development processes were too slow to keep changes.”
up with market innovation demands.
R. S. Rathore,
General Manager of
Solution Research and Development,
Genus
Genus started working with TBM Consulting Group, Inc.
to implement LeanSigma™ tools and practices. Starting with
several highly focused kaizen events, the methodology has
touched every area of the company and transformed
the culture.

Results
Average product costs have been reduced 15-20%, output
doubled in the same floorspace, new products are being
launched in half the time, and revenues have grown five-
fold, capturing an estimated 22% of the Indian market for
its products.



Client Case Studies

Accellent Creates a Culture of Continuous Improvement

Client
Accellent is a provider of integrated outsourced manufacturing and
“ e were able to show the
W
engineering services to the medical device industry. The company
provides design and engineering services, precision component customer the difference on
fabrication, finished-device assembly and supply chain management. the plant floor right away.
After they saw how we were
Challenge doing lean, they became
a big believer, and we
Accellent benefited from the Six Sigma blackbelt training it started
started getting new product
in 2006, but company leaders suspected that the potential for greater
performance lay dormant in its hardworking teams at 17 facilities. So proposals coming our way.”
they began to search for a more holistic approach to training, one that Joe Panebianco,
would create a lasting culture of continuous improvement throughout Director –
the enterprise. The TBM Institute for
Operational Excellence
Solution
Partner with TBM’s Institute for Operational Excellence, planning a
series of eight-week on-site training modules to help build a culture of
continuous improvement. The Institute’s team works on:
• leadership development
• value stream mapping
• kaizen training and implementation
• certification training
• visual systems creation
• daily metrics monitoring plans

Results
Accellent achieved over $1.7 million in cost savings during the first five
months of continuous improvement training.



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