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Friday, January 31, 2014

Greenbelts Tackle Their First Kaizen

Day 3-5 out of the 5 days of Lean Sensei's Greenbelt Module 1 is spent at the gemba for practical application of the lean tools taught on day 1-2. Here at Lean Sensei, we have a practical approach to lean training. To truly learn the tools and methodologies, you have to use them!
This week, the Greenbelts are at a local trailer manufacturing company to apply their 5S know-how. The Greenbelts apply their skills in a real life company setting and the hosting company receive real savings.
Next, each Greenbelt candidate will need to complete a 5S project on their own without the rest of their classmates or a Lean Sensei coach. This project must be completed at their home organization. A minimum of 25% improvement is one of the criterion to receive a pass on this homework project.
Genchi gembutsu, go and see! 

Observing the current flow of work 

Learning about the needs of the process owner.

Thursday, January 30, 2014

2014 Program Dates Have Been Released

Are you ready for another year of lean?

We've already kicked off the year with a benchmarking tour of Vancouver, Greenbelt Operations and have Blackbelt and Greenbelt Service slated for the next couple of weeks.
But there are many more programs scheduled including some that are new this year. These new programs include Lean Deployment, Lean People Development, Greenbelt in Tulsa, USA and Juku workshops for Leanbelt Professional distinction.

Information on all our programs and all the dates are on our website. For additional information, you are always welcome to contact us: (604) 264-1000

Wednesday, January 29, 2014

The First Greenbelt Operations of 2014

This week at Lean Sensei, we kicked off our first Greenbelt Operations class of the year.
Experts in the realm of windows, doors, industrial pipes, electrical and food manufacturing and distribution are all gathered in Lean Sensei's training facility in Vancouver.

The first two days of Greenbelt will consist of coach Jake arming the class with the fundamentals of lean and a sound understanding of the basic tools of a lean practitioner such as 5S and 7 Wastes. Next the class will have to put these new tools to use at a local company in the lower mainland. The host company will have high expectations for the group as each kaizen team must achieve at least 25% improvement.

Constructing the perfect egg protecting apparatus
 Will the eggs survive the drop?

For this group, unfortunately not!
Group photo

Good luck with the kaizen!
We are still accepting registration for the Operations/Service Hybrid Greenbelt for Spring and Summer.

Greenbelt Operations (Toronto – Spring 2014)
Module 1: March 3rd – March 7th
Module 2: March 31st – April 4th
Module 3: April 28th – May 2nd
Greenbelt Hybrid Service and Operations (Vancouver – Spring 2014)
Module 1: March 10th – March 14th 
Module 2: April 7th – April 11th
Module 3: May 5th – May 9th
Greenbelt Operations (Calgary/Edmonton – Spring 2014)
Module 1: March 24th – March 28th (EDMONTON)
Module 2: April 28th – May 2nd (CALGARY)
Module 3: May 26th – May 30th (EDMONTON)
Greenbelt Hybrid Operations and Service (Vancouver – Summer 2014)
Module 1: May 12th – May 16th
Module 2: June 9th – June 13th
Module 3: July 7th – July 11th

Registration can be completed on our website:  

Tuesday, January 28, 2014

Executive Lean Strategy Session in Edmonton

The beginning of the week is a cold one for David, Master Coach who is currently in Edmonton facilitating an in-house specialized Lean Strategy session. This strategy session is customized to the particular training needs of our Edmonton based client.

The group is learning to used the VALUES strategy methodology in the two-day strategy session.
Vision and values... for lean!
Strategy board

Uplifting debrief and discussion

If you would like a customized lean training session held in your facility, contact us at (604) 264-1000 or

Monday, January 27, 2014

Zero Defects!

Poka Yoke, which literally translates to mistake proofing, is a tool that organizations can use to minimize errors, mistakes and defects.  But Poka Yoke actually falls under the larger category of zero defects or total quality. 

Lean Sensei's Poka Yoke/Mistake Proofing workshop covers both the general defect-prevention techniques and specific Poka Yoke tools. The Mistake Proofing workshop is a part of the Juku program.

Below are some cheat sheets and a template that the workshop participants learned to use on January 24, 2014. Dates for upcoming Juku workshops will be on our website:

Initial Poka Yoke game set up 

Continuous improvement to poka yoke to ensure a hole-in-one

Group photo

Friday, January 24, 2014

The Best of Vancouver

We've kicked off the year off reflecting and sharing our learnings and successes!

Tuesday and Wednesday was our two day tour of lean organizations in Vancouver. Personally selected by Lean Sensei, these companies demonstrated the manufacturing and service applications of lean.

From aerospace to banking to wholesale of delectable delights to sustainable wind power, power systems, helicopters and beautiful fireplaces, attendees learned how other local companies big and small dealt with employee buy-in, instilling not just lean tools but a culture of lean.

Cascade Aerospace share their journey.

All aboard the lean bus!

Safety notes before the Gemba walk.

Team generated communication boards at Alpha

Group photo at Heli-One

The next benchmarking tours which are part of our Executive Leanbelt certification are for Florida - February 18-20
Japan - April 14-17 and October 20-23
Europe  -May 26-30

Contact for more information.

Monday, January 20, 2014

TRANSFORM Methodology

Last week David facilitated an in-house lean training session with Florida's Regal Marine.

Attendees left the session armed and ready to utilize Lean Sensei's TRANSFORM methodology.
The TRANSFORM methodology is for high level lean strategy and goes hand in hand with the Extreme Make-Over methodology used in Blackbelt and Executive programs. The TRANSFORM methodology is used for New Product Introduction, Sales Increasing, Lean roll out and deployment of vision and values.

David's next trip to Florida will be February 18 to 20th for the Florida Benchmarking tour.
Email for details.

Thursday, January 16, 2014

Lean Benchmarking In North America

What a wonderful time for the attendees of our next benchmarking tour to visit Vancouver. Our fingers are crossed that the beautiful weather keeps up.

On January 21-22 Lean Sensei will host a tour around 6 of Vancouver and the lower mainland's lean facilities. Each company is hand picked by Lean Sensei to showcase different levels of lean and  different industries. 

We are all ready and looking forward to showcase the lean companies of Vancouver!

Though Vancouver Benchmarking is full, we are taking in registrations for Florida Benchmarking- taking place on February 18-20.

Jacksonville, Florida is a hub of companies passionate about lean. Visit our website, email or call us for more information:

Wednesday, January 15, 2014

Mistake Proofing

Poka-Yoke also known as mistake proofing or error proofing can be preventative or indicative in nature. Whether it is a device or piece of machinery that prevents the next step in the process from taking place until the previous step has been properly executed or an alert that indicates that a mistake has been made, we can find many existing examples.

Pressing the brake pedal in order to start the ignition of a car, the safety clamp being on as the default setting of BBQ starters, warning or confirmation pop-up windows on computers when deleting folders or auto-locking nozzles for chemical cleaning products are just a few examples in every day life.

Error proofing is a large component of quality assurance and a competitive edge for companies that recognize the importance of it. How can you build error proofing into your processes and systems?

Learn how Juku course, Lean Mistake Proofing one day course. All attendees must have at least Lean Sensei Greenbelt certification. 

This year the Juku course, Poka Yoke will be held on January 24, 2014
We can accept a few more last minute registrations via our website:
It is strongly suggested that you call our office to make sure that spots are still available prior to registering: (604) 264-1000

Lean Mistake Proofing is just one of the many topics you can gain expertise in through the Juku program. Call our office for upcoming dates:
  • Set-Up Time Reduction
  • People Development
  • Product Development
To learn more about how you can elevate your Greenbelt or Blackbelt certification to Professional status, visit the page on our website.

Thursday, January 9, 2014

Perfect Time to go to Florida

"Inspiring speakers, world class manufacturers, practical lessons that can be applied right away."
                                                                                   -Florida Benchmarking Tour 2013 participant

Our Florida Benchmarking Tour is back by popular demand for its third installment. And what better time to head south than in the winter.

Vancouver Benchmarking Tour:
February 18-20, 2014

We are currently accepting registration for this tour.

This is not your run-of-the-mill benchmarking tour. You will see lean applied in settings that you may not have expected, such as at the local Sheriff's office or the dentist. The application of lean in any and all industries is a testament of the city of Jacksonville's passion for lean. This city is home to some of the most lean organizations outside of Japan. It is not surprising that the next AME conference will be held in this city.

Don't miss your chance to get an insider's view of some of the world's most lean companies. 
(604) 264-1000

Below is a video about our North American benchmarking tours.

Wednesday, January 8, 2014

Photos of the day

... in beautiful Buntzen Lake here in Vancouver area.

Sunday, January 5, 2014

Funny video about 5 Why's

We came across this funny video about what "five why" is all about.... enjoy!

Wednesday, January 1, 2014