Region: UK

Lean Management System – LEVEL 1 – Japan Study Tour

About the visit

15  – 22 November 2025

Join the leading Lean Training Programme in Japan this November for an experience of a lifetime.

We are proud to offer you this unique opportunity to gain practical knowledge and experience studying with Toyota gurus for one whole week in Japan.

The Lean Management System study tour covers a comprehensive view of Lean leadership and the Lean Production System. The tour provides you with an opportunity to study in Toyota’s own training centre with direct access to Toyota trainers and Toyota  production facilities.

This is a once in a lifetime opportunity to boost your leadership and management skills by learning from the very best in the world. You will also obtain your Certificate directly from Toyota. We have created a study week that combines intense learning with both fun and cultural immersion!

Understand Why and How to use LEAN

This Study Tour will provide you with a deep understanding of how to make the best use of Lean. This is a unique opportunity to visit Japan, Toyota, and some of their suppliers to train in Lean through seminars, Gemba visits, and participating in practical training at Toyota’s own training facility. The objective is to dig deep into the WHAT, WHY and HOW of Lean Thinking. What are the elements needed to run a successful Lean system? Why is it so popular in current thinking and How can it influence your own organization and support growth.

By understanding the whole lean management system you will get an insight into what these leading Japanese companies are doing to compete in today’s fast changing environment.

You will learn to identify the tools and elements of Lean Methodology that can be applied to your own business to support profitable growth. The week in Japan will also provide an insight into Japanese culture and values.

Study Tour Package Includes:

  • Workshops and seminars
  • Study visits
  • Hotel Accommodation for the entire duration of the study visit
  • Local transfers in Japan
  • Full board Sunday – Friday
  • Farewell dinner

Costs & To Book

  •  £6,500 plus VAT, due to new restrictions we can advise on flights but not book on your behalf, pricing has been adjusted accordingly.
  • Onsite Host Companies: 10% Discount on all Bookings
  • Group Discount: 10% Discount on 4 or more places

Need Help or Advice?

For full terms and conditions and for details of our Company Insurance Policy please do contact us.

Any questions regarding the training, the travel to or within Japan – please do give us a call on +44 (0) 23 9246 8978.

The study tour is being delivered by SA Partners LLP and Onsite Insights in partnership with C2U Group.

Visit in 60 seconds / Awards

Lean Manufacturing … Company culture … Kanban … Kaizen … 5S … TPM … Visual Management … Managing full product lifecycle … Value stream mapping … Quality Problem Sheet … Five Whys? … Process flow … Environmental Management … Training & Development … Quality Control … Investor in People

Visit agenda

The training week will provide an invaluable insight into lean thinking. You will see it in action at Toyota and other leading-edge companies, where it originated and has matured over the last 100 years.

Learn the original thinking directly from former senior executives at Gifu Autobody, a Toyota-owned minivan manufacturer.  The Japanese sensei’s

(guru’s) will only teach based on real experience.

Time will be divided between the classroom, Gemba and practical workshops. The tour starts in the Nagoya region and ends in Tokyo, going from countryside to one of the largest cities in the world.

Saturday: Travel day

Some participants might need to leave on Friday to meet the start up on Sunday morning.

Sunday: Tour Opening

We will take the opportunity to recover from jetlag and relax after the long flight by visiting the Toyota Commemorative Museum of Industry and Technology where we also will have lunch. In the museum we can follow the Japanese industrial history from looms to robotics. After the visit we travel to the destination of the day, Kakamigahara, where we will stay until Friday. The day ends with a common dinner and introduction of the week.

Monday: Training

The first day of training introduces the Production System by our host for the week. A Japanese senior manager will lead us through Toyota Production System from a manager perspective. From values, mindset to specific tools and methods. This session will prepare the group in what we can expect from the study visits, from the practice and from the following sessions. Your overall picture of the production system will be confirmed or completed. In the afternoon we go for a first study visit, guided by our sensei. Q&A. Common dinner.

Tuesday: Training

Next day, we continue to dig deeper into aspects of the production system and the Toyota way of managing and leading. How are all the puzzle pieces connected?
How is Kaizen work organized and performed? Etc. After lunch, we go for another study visit and if time allows, we will also end with a visit to a traditional knife maker. Common dinner.

Wednesday: Training

This day we spend in the Training Center where Toyota train their own people. We will increase our knowledge of Kanban when the group take part in a Kanban Role Play and we will train in how to perform a productivity improvement task following the Toyota methods. Common dinner.

Thursday: Training

We will start with a study visit before spending the rest of the day with a final Q&A and concluding the learnings for the week. Presentation by all participants. Common dinner.

Friday: Conclusion

The last day ends with a study visit. We do final reflections before we board the bullet train that will take us to Tokyo. Free evening in Tokyo. Common farewell dinner.

Saturday/Sunday: Tokyo

Free day/departure. Possibility to extend stay.

Lean Management System – LEVEL 1 – Japan Study Tour

About the visit

10 – 17 May 2025

Join the leading Lean Training Programme in Japan this May for an experience of a lifetime.

We are proud to offer you this unique opportunity to gain practical knowledge and experience studying with Toyota gurus for one whole week in Japan.

The Lean Management System study tour covers a comprehensive view of Lean leadership and the Lean Production System. The tour provides you with an opportunity to study in Toyota’s own training centre with direct access to Toyota trainers and Toyota  production facilities.

This is a once in a lifetime opportunity to boost your leadership and management skills by learning from the very best in the world. You will also obtain your Certificate directly from Toyota. We have created a study week that combines intense learning with both fun and cultural immersion!

Understand Why and How to use LEAN

This Study Tour will provide you with a deep understanding of how to make the best use of Lean. This is a unique opportunity to visit Japan, Toyota, and some of their suppliers to train in Lean through seminars, Gemba visits, and participating in practical training at Toyota’s own training facility. The objective is to dig deep into the WHAT, WHY and HOW of Lean Thinking. What are the elements needed to run a successful Lean system? Why is it so popular in current thinking and How can it influence your own organization and support growth.

By understanding the whole lean management system you will get an insight into what these leading Japanese companies are doing to compete in today’s fast changing environment.

You will learn to identify the tools and elements of Lean Methodology that can be applied to your own business to support profitable growth. The week in Japan will also provide an insight into Japanese culture and values.

Study Tour Package Includes:

  • Workshops and seminars
  • Study visits
  • Hotel Accommodation for the entire duration of the study visit
  • Local transfers in Japan
  • Full board Sunday – Friday
  • Farewell dinner

Costs & To Book

  •  £6,500 plus VAT, due to new restrictions we can advise on flights but not book on your behalf, pricing has been adjusted accordingly.
  • Onsite Host Companies: 10% Discount on all Bookings
  • Group Discount: 10% Discount on 4 or more places

Need Help or Advice?

For full terms and conditions and for details of our Company Insurance Policy please do contact us.

Any questions regarding the training, the travel to or within Japan – please do give us a call on +44 (0) 23 9246 8978.

The study tour is being delivered by SA Partners LLP and Onsite Insights in partnership with C2U Group.

Visit in 60 seconds / Awards

Lean Manufacturing … Company culture … Kanban … Kaizen … 5S … TPM … Visual Management … Managing full product lifecycle … Value stream mapping … Quality Problem Sheet … Five Whys? … Process flow … Environmental Management … Training & Development … Quality Control … Investor in People

Visit agenda

The training week will provide an invaluable insight into lean thinking. You will see it in action at Toyota and other leading-edge companies, where it originated and has matured over the last 100 years.

Learn the original thinking directly from former senior executives at Gifu Autobody, a Toyota-owned minivan manufacturer.  The Japanese sensei’s

(guru’s) will only teach based on real experience.

Time will be divided between the classroom, Gemba and practical workshops. The tour starts in the Nagoya region and ends in Tokyo, going from countryside to one of the largest cities in the world.

Saturday: Travel day

Some participants might need to leave on Friday to meet the start up on Sunday morning.

Sunday: Tour Opening

We will take the opportunity to recover from jetlag and relax after the long flight by visiting the Toyota Commemorative Museum of Industry and Technology where we also will have lunch. In the museum we can follow the Japanese industrial history from looms to robotics. After the visit we travel to the destination of the day, Kakamigahara, where we will stay until Friday. The day ends with a common dinner and introduction of the week.

Monday: Training

The first day of training introduces the Production System by our host for the week. A Japanese senior manager will lead us through Toyota Production System from a manager perspective. From values, mindset to specific tools and methods. This session will prepare the group in what we can expect from the study visits, from the practice and from the following sessions. Your overall picture of the production system will be confirmed or completed. In the afternoon we go for a first study visit, guided by our sensei. Q&A. Common dinner.

Tuesday: Training

Next day, we continue to dig deeper into aspects of the production system and the Toyota way of managing and leading. How are all the puzzle pieces connected?
How is Kaizen work organized and performed? Etc. After lunch, we go for another study visit and if time allows, we will also end with a visit to a traditional knife maker. Common dinner.

Wednesday: Training

This day we spend in the Training Center where Toyota train their own people. We will increase our knowledge of Kanban when the group take part in a Kanban Role Play and we will train in how to perform a productivity improvement task following the Toyota methods. Common dinner.

Thursday: Training

We will start with a study visit before spending the rest of the day with a final Q&A and concluding the learnings for the week. Presentation by all participants. Common dinner.

Friday: Conclusion

The last day ends with a study visit. We do final reflections before we board the bullet train that will take us to Tokyo. Free evening in Tokyo. Common farewell dinner.

Saturday/Sunday: Tokyo

Free day/departure. Possibility to extend stay.

Fujifilm Speciality Ink Systems

About the visit

Located in Broadstairs, UK, the FUJIFILM Speciality Ink Systems site is a centre of excellence for the development of UV and aqueous inkjet ink technologies and manufacture of UV inks. The facility manufactures for both Fujifilm print systems and other print system manufacturers. In addition, it has expertise in screen, flexo, and industrial analogue inks. It is part of the global FUJIFILM Ink Solutions Group, with locations across UK, USA and India.

 

The site holds certifications in ISO 9001, ISO 14001, ISO 45001, and ISO 22000, underscoring its commitment to stringent quality management and environmental standards. It also has GMP manufacturing capability.

 

Quality assurance is central to the site’s operations, with a focus on delivering products that meet the highest performance requirements. Analytical methodology and equipment is used to control the quality of raw materials at a molecular level. Stringent Quality Management Systems ensure that products undergo rigorous quality checks throughout production.

 

A strong emphasis on continuous improvement, includes various programs that enhance efficiency and optimize manufacturing processes. The Autonomous Maintenance program empowers production personnel to take ownership of their equipment, ensuring optimal performance and minimizing downtime. One Point Lessons equip operators with valuable knowledge and practical solutions, preventing human errors and resolving process problems effectively. The Quick Kaizen approach facilitates swift implementation of small but impactful improvements.

 

Additionally, the site’s commitment to sustainability is evident through its goal of reducing CO2 generation by 50% compared to 2019 by 2030, with an ultimate objective of achieving carbon neutrality by 2040. It is a certified zero-to-landfill site.

 

Supported by robust manufacturing processes and a reliable supply chain, the site delivers batch-to-batch consistency and quality-assured products. With its strong manufacturing and logistics infrastructure, it guarantees uninterrupted global supply to 86 countries.

Visit in 60 seconds / Awards

Quality Journey … Projects and People … Communication … Training …  Culture … Industry

Visit agenda

10.00 Arrival & Refreshments

10.15 Welcome & Introductions

10.30 About Fujifilm SIS
– Our Company
– Our Culture
– Our Industry

11.30 Our Quality Journey
– Our Approach
– Projects & Initiatives
– Tools & Techniques
– The FSIS House of Lean
– What’s Next!

12.30 Networking Lunch

13.00 Site Tour

14.00 Projects & People
– Communication
– Projects & Results
– Training at Fujifilm

15.30 Ideas Exchange (Q&A)

16.00 Feedback, Close & Depart

Fujifilm Speciality Ink Systems

About the visit

Located in Broadstairs, UK, the FUJIFILM Speciality Ink Systems site is a centre of excellence for the development of UV and aqueous inkjet ink technologies and manufacture of UV inks. The facility manufactures for both Fujifilm print systems and other print system manufacturers. In addition, it has expertise in screen, flexo, and industrial analogue inks. It is part of the global FUJIFILM Ink Solutions Group, with locations across UK, USA and India.

 

The site holds certifications in ISO 9001, ISO 14001, ISO 45001, and ISO 22000, underscoring its commitment to stringent quality management and environmental standards. It also has GMP manufacturing capability.

 

Quality assurance is central to the site’s operations, with a focus on delivering products that meet the highest performance requirements. Analytical methodology and equipment is used to control the quality of raw materials at a molecular level. Stringent Quality Management Systems ensure that products undergo rigorous quality checks throughout production.

 

A strong emphasis on continuous improvement, includes various programs that enhance efficiency and optimize manufacturing processes. The Autonomous Maintenance program empowers production personnel to take ownership of their equipment, ensuring optimal performance and minimizing downtime. One Point Lessons equip operators with valuable knowledge and practical solutions, preventing human errors and resolving process problems effectively. The Quick Kaizen approach facilitates swift implementation of small but impactful improvements.

 

Additionally, the site’s commitment to sustainability is evident through its goal of reducing CO2 generation by 50% compared to 2019 by 2030, with an ultimate objective of achieving carbon neutrality by 2040. It is a certified zero-to-landfill site.

 

Supported by robust manufacturing processes and a reliable supply chain, the site delivers batch-to-batch consistency and quality-assured products. With its strong manufacturing and logistics infrastructure, it guarantees uninterrupted global supply to 86 countries.

Visit in 60 seconds / Awards

Quality Journey … Projects and People … Communication … Training …  Culture … Industry

Visit agenda

10.00 Arrival & Refreshments

10.15 Welcome & Introductions

10.30 About Fujifilm SIS
– Our Company
– Our Culture
– Our Industry

11.30 Our Quality Journey
– Our Approach
– Projects & Initiatives
– Tools & Techniques
– The FSIS House of Lean
– What’s Next!

12.30 Networking Lunch

13.00 Site Tour

14.00 Projects & People
– Communication
– Projects & Results
– Training at Fujifilm

15.30 Ideas Exchange (Q&A)

16.00 Feedback, Close & Depart

Vale

About the visit

The Vale Clydach Refinery located near Swansea in South Wales, is one of Europe’s largest nickel refineries, producing high purity nickel pellet and powder products for specialist applications such as high nickel alloys, batteries, nickel plating and automotive components. They supply over 280 customers in over 30 countries worldwide (Europe, Asia and USA). Their Continuous Improvement (CI) approach has been based around specific tools: Standard Work, 5S, TPM, OEE, QCO and Six Sigma.

Winner of the prestigious Shingo silver medallion in 2014.

Continuous Improvement Journey to Shingo Silver medallion win
__________________________________________________

The site has been on a CI & Operational Excellence journey since 2008 and are proud of their achievements. Employees have been trained in CI tools such as problem solving and are encouraged to apply this learning in their work team. Key to their success has been engaging their employees to contribute improvement ideas and participate in their implementation. The visit will be an opportunity for them to share these experiences and what they have learnt along the way, through to being awarded the Shingo Silver medallion for Operational Excellence in January 2014.

Corporate Social Responsibility
_____________________________

The Clydach Refinery is justly proud of their environmental record. In 2014 99.9% of all waste has been diverted from landfill, with 77% re-used or recycled. With a 100 year history, it is important to us that we maintain good Community relations. This visit will focus on the improvements we have made and what we do to contribute and engage with our Community.

Visual Management – ‘Yellow Boards’
________________________________

Throughout Clydach Refinery, Continuous Improvement “Yellow Boards” are used to:

– Cascade Refinery strategy into meaningful activities for each work team.

– Track KPI’s and action plans.

– Action important issues, escalating items where appropriate.

– Enhance communication within team, and allow employees to provide feedback.

– Cascade expectations around the behaviours needed to sustain our CI culture.

– Recognise team success.

They will share the process with you and during a tour of the Refiner you will have the opportunity to see the Yellow Boards in practice

​

Visit in 60 seconds / Awards

World Class Manufacturing … Lean Manufacturing … Engagement & Behaviours … Sustainability & Environment … Shingo Winner

Visit agenda

09.45: Arrival & refreshments
10.00: Welcome & introductions
10.30: Overview of the Refinery and our CI Journey
11.15: Refreshment Break
11.30: Corporate Social responsibility
12.30:Lunch
13.15: Site Tour
14.45: Questions & Answers session
15.30: Close & Depart

DHL Supply Chain

About the visit

DHL Supply Chain, part of the DPDHL Group is the World’s leading logistics provider.  Combining management and value-added services with customised, integrated logistics solutions drives resilience, efficiency, improves quality and creates competitive advantage.  DHL Supply Chain operates in 50+ countries with over 177,000 full-time employees.  Ensuring outstanding and sustainable operations requires the best people.  That’s why DHL strives to provide a safe, inclusive and purpose-driven workplace rooted in the guiding principles of Respect and Results – values that form the foundation of everything they do.

 

The DHL Coalville facility is a 250,000ft2 multi-Customer Distribution Centre within the Technology sector located in the Midlands area.

 

DHL Supply Chain drives Continuous Improvement and world class operational efficiency through the implementation of their BASICS Standards and Operations Management System.  These ‘BASICS’ are their sets of tools and processes which define the DHL ‘Way of Working’.  This creates a platform from which to implement their Operations Management System.  A system which ensures they deliver a world class operation that reaches its maximum performance potential.  They embed a culture of Continuous Improvement, which involves everyone, everywhere, everyday taking responsibility for it using the OMS First Choice toolkit.

Visit in 60 seconds / Awards

Operations Management System … Continuous Improvement … Tools … Methodology

Visit agenda

10:30 Arrival & Coffee

  • Introduction and Overview of Coalville facility
  • DHL Operations Management System – how we use OMS to deliver for our Customers
  • Site Tour
  • Lunch
  • Continuous Improvement at DHL
  • Q&A

15:00 Close

DHL Supply Chain

About the visit

DHL Supply Chain, part of the DPDHL Group is the World’s leading logistics provider.  Combining management and value-added services with customised, integrated logistics solutions drives resilience, efficiency, improves quality and creates competitive advantage.  DHL Supply Chain operates in 50+ countries with over 177,000 full-time employees.  Ensuring outstanding and sustainable operations requires the best people.  That’s why DHL strives to provide a safe, inclusive and purpose-driven workplace rooted in the guiding principles of Respect and Results – values that form the foundation of everything they do.

 

The DHL Coalville facility is a 250,000ft2 multi-Customer Distribution Centre within the Technology sector located in the Midlands area.

 

DHL Supply Chain drives Continuous Improvement and world class operational efficiency through the implementation of their BASICS Standards and Operations Management System.  These ‘BASICS’ are their sets of tools and processes which define the DHL ‘Way of Working’.  This creates a platform from which to implement their Operations Management System.  A system which ensures they deliver a world class operation that reaches its maximum performance potential.  They embed a culture of Continuous Improvement, which involves everyone, everywhere, everyday taking responsibility for it using the OMS First Choice toolkit.

Visit in 60 seconds / Awards

Operations Management System … Continuous Improvement … Tools … Methodology

Visit agenda

10:30 Arrival & Coffee

  • Introduction and Overview of Coalville facility
  • DHL Operations Management System – how we use OMS to deliver for our Customers
  • Site Tour
  • Lunch
  • Continuous Improvement at DHL
  • Q&A

15:00 Close

Lear Corporation

About the visit

Lear is the world leader in luxury and performance seating for the automotive industry.  Supplying the majority of the world’s leading manufacturers, they have established a reputation for superior engineering, excellence in manufacturing and craftmanship. The organisation was named as one of the Fortune’s 2023 Most Admired Companies. Seating is built to order on a just in time basis and the site manages over 3000 product variations over 2 build lines.  Redditch is an assembly plant and the sole supplier of seating for one of the UK’s most prodigious car brands.

The Redditch site was purchased by Lear in 2010 and they rapidly created a centre of excellence.  On the visit you will see excellent standards of:

  • Workplace organisation (Five S)
  • Visual Management
  • Lean Tools & Techniques
  • Digital SOP’s and poke yoke
  • Takt & product flow
  • Tiered Management System
  • Obeya – Central Control room

Employee engagement is achieved through both their Kaizen initiative and also their TIC (Team Improvement Circle) program delivered in partnership with their key customer.  They have developed a training academy on site with a capability centre within the factory environment.  Learning and engagement is also encouraged through bite-sized learning; lunch & learns and line-side development.

Visit in 60 seconds / Awards

Workplace organisation…Visual Management… Lean Tools & Techniques …Digital SOP’s and poke yoke  …Takt & product flow…Tiered Management System…Obeya – Central Control room

Visit agenda

09:45: Arrival & Welcome

10.00:  Lear – Our Heritage

10.30:  Our Continuous Improvement Journey

11.15:   Refreshment Break

11.30:   Site Tour – Lean/CI/Visual Management

12.30:   Site Tour – OHNO Circles

12.45:   Feedback on OHNO Circles

13.00:   Lunch

13.30:   Employee Engagement – TIC & Kaizen

14.00:   Round Table Discussion

14.45:   Feedback

15.00:   Close

Lear Corporation

About the visit

Lear is the world leader in luxury and performance seating for the automotive industry.  Supplying the majority of the world’s leading manufacturers, they have established a reputation for superior engineering, excellence in manufacturing and craftmanship. The organisation was named as one of the Fortune’s 2023 Most Admired Companies. Seating is built to order on a just in time basis and the site manages over 3000 product variations over 2 build lines.  Redditch is an assembly plant and the sole supplier of seating for one of the UK’s most prodigious car brands.

The Redditch site was purchased by Lear in 2010 and they rapidly created a centre of excellence.  On the visit you will see excellent standards of:

  • Workplace organisation (Five S)
  • Visual Management
  • Lean Tools & Techniques
  • Digital SOP’s and poke yoke
  • Takt & product flow
  • Tiered Management System
  • Obeya – Central Control room

Employee engagement is achieved through both their Kaizen initiative and also their TIC (Team Improvement Circle) program delivered in partnership with their key customer.  They have developed a training academy on site with a capability centre within the factory environment.  Learning and engagement is also encouraged through bite-sized learning; lunch & learns and line-side development.

Visit in 60 seconds / Awards

Workplace organisation…Visual Management… Lean Tools & Techniques …Digital SOP’s and poke yoke  …Takt & product flow…Tiered Management System…Obeya – Central Control room

Visit agenda

09:45: Arrival & Welcome

10.00:  Lear – Our Heritage

10.30:  Our Continuous Improvement Journey

11.15:   Refreshment Break

11.30:   Site Tour – Lean/CI/Visual Management

12.30:   Site Tour – OHNO Circles

12.45:   Feedback on OHNO Circles

13.00:   Lunch

13.30:   Employee Engagement – TIC & Kaizen

14.00:   Round Table Discussion

14.45:   Feedback

15.00:   Close

Lear Corporation

About the visit

Lear is the world leader in luxury and performance seating for the automotive industry.  Supplying the majority of the world’s leading manufacturers, they have established a reputation for superior engineering, excellence in manufacturing and craftmanship. The organisation was named as one of the Fortune’s 2023 Most Admired Companies. Seating is built to order on a just in time basis and the site manages over 3000 product variations over 2 build lines.  Redditch is an assembly plant and the sole supplier of seating for one of the UK’s most prodigious car brands.

The Redditch site was purchased by Lear in 2010 and they rapidly created a centre of excellence.  On the visit you will see excellent standards of:

  • Workplace organisation (Five S)
  • Visual Management
  • Lean Tools & Techniques
  • Digital SOP’s and poke yoke
  • Takt & product flow
  • Tiered Management System
  • Obeya – Central Control room

Employee engagement is achieved through both their Kaizen initiative and also their TIC (Team Improvement Circle) program delivered in partnership with their key customer.  They have developed a training academy on site with a capability centre within the factory environment.  Learning and engagement is also encouraged through bite-sized learning; lunch & learns and line-side development.

Visit in 60 seconds / Awards

Workplace organisation…Visual Management… Lean Tools & Techniques …Digital SOP’s and poke yoke  …Takt & product flow…Tiered Management System…Obeya – Central Control room

Visit agenda

09:45: Arrival & Welcome

10.00:  Lear – Our Heritage

10.30:  Our Continuous Improvement Journey

11.15:   Refreshment Break

11.30:   Site Tour – Lean/CI/Visual Management

12.30:   Site Tour – OHNO Circles

12.45:   Feedback on OHNO Circles

13.00:   Lunch

13.30:   Employee Engagement – TIC & Kaizen

14.00:   Round Table Discussion

14.45:   Feedback

15.00:   Close

TRUMPF Laser UK Ltd

About the visit

TRUMPF has been a Family business since 1923. Innovation and technology leading is important to TRUMPF’s strategy. With nearly 15,000 employees worldwide and revenue over 3.5 billion Euros there is a global manufacturing network, all linked and optimised by SYNCHRO (TRUMPF’s Lean model).

In additional to Laser manufacture, TRUMPF produce Machine tools for cutting and bending materials. Other business fields include Additive manufacturing, Photonic components and Extreme Ultra Violet lasers (used in semiconductor manufacture).

TRUMPF UK Laser Ltd (aka TGBL) is growing and evolving with many new, “sustainable” markets finding applications for Pulsed Laser products, such as components for electric mobility.

TGBL (formerly SPI Lasers) is fully integrated into TRUMPF’s Production network as a Customer and Supplier to other TRUMPF subsidiaries. TGBL also sell directly to non-TRUMPF Customers.

TruPulse nano Products (one of the three Product Value Streams at TGBL) represent high volume Production within the TRUMPF network and have leveraged SYNCHRO methodologies to focus on one piece flow, levelled Production and linked planning triggers to minimise inventory and increase flexibility.

An in-house designed MES system enables structure and transparency to Production status and capacity.

You will see a Production line and workstations designed to eliminate waste and provide transparency. Monitored with simple shopfloor management and complex, deep dive data from MES to optimise and redesign.

The visit will focus on Unit 4 in Southampton. There are two other Production units in Southampton, for other Product line assembly and Fibre Production. There is also a Production site in Rugby, who is both a Customer and Supplier to Southampton Cells.

Visit in 60 seconds / Awards

Lean Manufacturing … One Piece Flow … Visual Management … Just in Time … production planning and linked cells … Kanban … Process Improvement … MES system … Workstation design …Takt

Visit agenda

09.30: Arrival & Welcome

10.00: Overview of TRUMPF Group

10.30: Gemba Production line Tour

11.30: Continuous Improvement & SFM (SYNCHRO)

12.00: Gemba CI in Action

12.30: Lunch

13.00: CI Projects at TRUMPF UK & Target Conditions

14.00: Review & Feedback

14.30: Close & Depart

BAE Systems

About the visit

BAE Systems in Rochester, Kent is home to the organisations Electronic Systems Division. This site has been designing, manufacturing and supporting aerospace and avionics products for more than 70 years. Electronic Systems spans the commercial and defence electronics markets with a broad portfolio of missioncritical electronic systems, including flight and engine controls, electronic warfare and night vision systems; surveillance and reconnaissance sensors; secure networked communications equipment, and power and energy management systems. Their customers include the US and UK Defence Forces as well as an increasingly broad spectrum of commercial clients both in the UK and around the world.

Lean Manufacturing
__________________

BAE’s lean transformation has embraced many of the lean six sigma concepts, tools and behaviours. On the visit they will share with visitors their journey which has enabled them to transform how they operate, reduce costs and waste.

Design for Manufacture (DFM) Prototyping & 3D Printing
_________________________________________________

DFM and the use of 3D printing has allowed BAE Systems to reduce their New Product Development time down by 50%. This visit will provide an overview of the DFM process and also their approach to prototyping and 3D printing.

Culture of Change, BIT and the Shingo Journey
_________________________________________

Just over five years ago, the site recognise that for it to survive it needed to change its employees mindsets. This led to a focus on the culture and a commitment to innovation and best practice which has culminated in the application for the Shingo Prize — The Shingo Prize is generally accepted as the world’s leading award for Operational Excellence.

Visit in 60 seconds / Awards

Lean tools & techniques…World class manufacturing…DFM Prototyping…Supply chain management and integration…Company culture…3D Printing

Visit agenda

09.00  Arrival & Signing in​

09.15   Introductions & Site Overview​

09.30  Facility Tour & Simulation​

11.30   DFx & Innovation​

12.15    Networking Lunch​

13.00   Innovation through Prototyping & Collaboration​

14.00   Digital Transformation​

14.30   Empowering people for innovation and quality​

15.30    Feedback​

16.00   Close

Marshalls

About the visit

Marshalls is the UK’s leading supplier of concrete and natural stone products for external landscaping. We manufacture products for both commercial and domestic markets, including paving, block paving, kerb and edgings, drainage and water management solutions, protective street furniture, lighting, concrete bricks, masonry, walling and mortar.

The Marshall’s vision is to “Create Better Spaces” and “Futures for everyone”, socially, environmentally and economically.

Marshall’s are 4 years into a Continuous Improvement Journey that has embraced Lean as well as SHINGO principles.  They have deployed and engaged their teams in the delivery or waste reduction projects and seen a significant return on investment; increased engagement and improved productivity. On the visit Marshalls will share their journey and you will get to see some of the individual projects and programmes that have changed the way that they work.

Visit in 60 seconds / Awards

OpEx … Employee Development … Maturity Assessment … Continuous Improvement … Environmental Responsibility

Visit agenda

09:30 Arrival

09:45 Welcome & Introductions

10:00 Business Overview / Who are Marshalls

11:00 The Marshalls Way (OpEx Model)

12:00 Networking Lunch

13:00 Go & See Tour

14:00 LEAD – Employee Development

14.30 Marshalls Maturity Assessment (MMA)

15:00 Feedback Session

15:30 Close

Marshalls

About the visit

Marshalls is the UK’s leading supplier of concrete and natural stone products for external landscaping. We manufacture products for both commercial and domestic markets, including paving, block paving, kerb and edgings, drainage and water management solutions, protective street furniture, lighting, concrete bricks, masonry, walling and mortar.

The Marshall’s vision is to “Create Better Spaces” and “Futures for everyone”, socially, environmentally and economically.

Marshall’s are 4 years into a Continuous Improvement Journey that has embraced Lean as well as SHINGO principles.  They have deployed and engaged their teams in the delivery or waste reduction projects and seen a significant return on investment; increased engagement and improved productivity. On the visit Marshalls will share their journey and you will get to see some of the individual projects and programmes that have changed the way that they work.

Visit in 60 seconds / Awards

OpEx … Employee Development … Maturity Assessment … Continuous Improvement … Environmental Responsibility

Visit agenda

09:30 Arrival

09:45 Welcome & Introductions

10:00 Business Overview / Who are Marshalls

11:00 The Marshalls Way (OpEx Model)

12:00 Networking Lunch

13:00 Go & See Tour

14:00 LEAD – Employee Development

14.30 Marshalls Maturity Assessment (MMA)

15:00 Feedback Session

15:30 Close

Buhler Group

About the visit

Buhler is a world leader in innovation and delivery of sorting solutions to the global food and non-food processing industries. They design, manufacture and supply optical sorting machines to over 100 countries throughout the world. The machines are used to detect and remove unwanted and blemished material from products such as rice, coffee, nuts, vegetables, etc. They are a low volume, high value, high technology assembly operation utilising modern manufacturing techniques.

Lean Manufacturing
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Buhler builds its machines on a production line which operates to a Takt. More than 10 major product types and a range of options are built, tested, packed and dispatched in an integrated, single piece flow system.

Lean Techniques such as shadow boards for tools, the supply of materials using Kanbans, the grouping of material requirements into kits, and the involvement of staff in sustained and continuous improvement are employed.

Visual Management is used in the whole supply chain from product enquiry through to product ordering, manufacture and dispatch, providing all functional areas with a consistent information base. Visual management is also used to track progress against plan, and identify and action variances.

The major drive for Lean Manufacturing is the reduction in throughput times for the factory, where a 50% improvement has already been achieved. There is also an emphasis on high standards in 5S.

People and Leadership
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Buhler has benefited from the introduction of a flat organisational structure, empowering its workforce, teamworking and greatly improved internal communications. More recently Buhler Sortex has begun rolling out competency-based job descriptions and performance appraisals. These changes, their objectives and what has been achieved will be shared with visitors.

Customer Relationship Management and Support
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The pre-sales and after-sales performance of Buhler Sortex is delivered through its extensive global sales and service organisation that consists of skilled personnel, state-of-the-art systems (CRM software; remote machine monitoring technologies) and efficient business processes (market analysis, sales lead generation, sales quotation, corrective action processes and so on)

Visit in 60 seconds / Awards

Customer Care … After sales service … Lean Manufacturing … Single piece flow … Shadow Boards for Tools … Kanban … Kaizen Events … OEE … Visual Management … Process Flow … Five S (5S) … Waste reduction … Organisational structure … Teamworking … Communications … Culture change

Visit agenda

10:00: Arrival & Welcome​

            Safety & Introductions​

10:20: Buhler Company Overview

10:30: Optical Sorting & Video

            Product Demonstration

11:00:  Buhler Manufacturing Highlights​

12:15:  Lunch​

13:00: Factory Tour

14:00: Group Feedback​

15:00: Close ​

Double H Nurseries

About the visit

Double H Nursery grows & supplies flowering houseplants for the major supermarkets such as Marks & Spencer, Waitrose and Sainsburys. They have been an accredited Investor in People since 1997 and this reflects their commitment to developing their staff at every level of the business. They have been on an ongoing lean journey for over 15 years and have introduced many tools and techniques used in wider manufacturing industries. They were one of the first companies within their sector to pursue Lean and Best Practice and it has become a way of life within the organization.

Over the last five years they have invested in digitalising operational processes to remove paperwork, save time and improve data quality to generate more insight. Using cloud computing, web-based apps and mobile technology they have made big efficiency improvements for relatively small investments

Lean Manufacturing
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We are in the process of ‘Lean Transformation’ within the horticultural industry. Changing the thought process from “we work with dirt, so it will be dirty”, to a culture of continuous and sustained improvement, and a sense of pride in the workplace. Many of their team leaders have achieved NVQ level 3 in management and there is an ongoing training program to continually develop the team. They are committed to limiting the negative environmental impact of the business and to this end use predominantly biological methods for crop protection against pest and disease, rather than conventional methods.

Operations Technology
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Using tech to improve operational efficiency though the use of custom apps and the elimination of paperwork from key business processes. Double H have built and deployed several apps and will talk more about how they have used these low and no-code solutions to support their digital transformation.

Visit in 60 seconds / Awards

Lean Manufacturing … 5S … Kanban … Kaizen … TPM … Visual Management … Skills matrix … Six monthly lean audit … Suggestion board/scheme … Investors in People … Waste reduction … Quality … Environmental impacts … Horticultural industry best practice

Visit agenda

10.00 Arrival and Refreshments

10.30 Welcome and Introductions

10.45 Double H Lean Story

11.45 Site Walk

13.00 Networking Lunch

13:30 Process Digitalisation

14.30 Questions and Answers

15.00 Close & Depart

Cummins Power

About the visit

Cummins is a world leader in the design and manufacture of engines and power generation equipment, including PowerCommand standby and prime power systems. The site also provides single-source warranty, planned maintenance, and round-the-clock emergency service 24 hours a day, seven days a week including back-up power rental through our network of distributors.

There are five operating segments:

– Engine
– Power Systems
– Components
– Distribution
– Electrified Power

At Daventry, the plant manufactures automotive engines used in heavy and medium trucks, bus and off highway vehicles. The site also manufactures light duty automotive. More recently the site has also begun manufacture of the power generation systems (Gensets) which are used in a variety of environments including rail, mining, oil and gas and commercial marine.

Manufacturing processes on site include: Machining of blocks, Assembly build, Sub-assembly, Paint, Final Test.

Visit in 60 seconds / Awards

Lean Manufacturing … Continuous Improvement … Continuous Flow Line … Takt Time … Visual Management … Problem Solving Boards … Employee Engagement … Culture Change … Planned Maintenance … SOPs (Standard Work) … Suggestion Scheme … Kanban … Five S

Visit agenda

10.00: Arrival & Welcome

  • This is Cummins Daventry
  • CI evolution and where we are today
  • Plant tour
  • Lunch
  • Industry 4.0 Digital Manufacturing
  • Quality 4.0
  • Q&A

15.00: Close & Depart

Cummins Power

About the visit

Cummins is a world leader in the design and manufacture of engines and power generation equipment, including PowerCommand standby and prime power systems. The site also provides single-source warranty, planned maintenance, and round-the-clock emergency service 24 hours a day, seven days a week including back-up power rental through our network of distributors.

There are five operating segments:

– Engine
– Power Systems
– Components
– Distribution
– Electrified Power

At Daventry, the plant manufactures automotive engines used in heavy and medium trucks, bus and off highway vehicles. The site also manufactures light duty automotive. More recently the site has also begun manufacture of the power generation systems (Gensets) which are used in a variety of environments including rail, mining, oil and gas and commercial marine.

Manufacturing processes on site include: Machining of blocks, Assembly build, Sub-assembly, Paint, Final Test.

Visit in 60 seconds / Awards

Lean Manufacturing … Continuous Improvement … Continuous Flow Line … Takt Time … Visual Management … Problem Solving Boards … Employee Engagement … Culture Change … Planned Maintenance … SOPs (Standard Work) … Suggestion Scheme … Kanban … Five S

Visit agenda

10.00: Arrival & Welcome

  • This is Cummins Daventry
  • CI evolution and where we are today
  • Plant tour
  • Lunch
  • Industry 4.0 Digital Manufacturing
  • Quality 4.0
  • Q&A

15.00: Close & Depart

SHINGO Forum Virtual Meet-Up

About the visit

The Shingo Forum exists to encouraging the sharing of ideas and inspiration between organizations. This virtual networking group meets monthly and includes a guest speaker; interactive workshop and expert facilitation.

There is no cost to join, but to participate you need to have an interest in Continuous Improvement and Enterprise Excellence. If you are interested in registering for the Forum please do email info@shingoforum.org

Join Now

This monthly virtual forum will provide you with a chance to hear from Shingo Facilitators, Examiners and Award-Winners.

  • Benchmarking
  • Sharing ideas & Inspiration
  • Networking (in a fun way – no selling!)
  • Discounts to Best Practice Visits
  • Access to Webinar Recordings & Resources

Guest Speaker: TBC

Hosted By: John Quirke – Shingo Facilitator

SHINGO Forum Virtual Meet-Up

About the visit

The Shingo Forum exists to encouraging the sharing of ideas and inspiration between organizations. This virtual networking group meets monthly and includes a guest speaker; interactive workshop and expert facilitation.

There is no cost to join, but to participate you need to have an interest in Continuous Improvement and Enterprise Excellence. If you are interested in registering for the Forum please do email info@shingoforum.org

Join Now

This monthly virtual forum will provide you with a chance to hear from Shingo Facilitators, Examiners and Award-Winners.

  • Benchmarking
  • Sharing ideas & Inspiration
  • Networking (in a fun way – no selling!)
  • Discounts to Best Practice Visits
  • Access to Webinar Recordings & Resources

Guest Speaker: TBC

Hosted By: John Quirke – Shingo Facilitator

SHINGO Forum Virtual Meet-Up

About the visit

The Shingo Forum exists to encouraging the sharing of ideas and inspiration between organizations. This virtual networking group meets monthly and includes a guest speaker; interactive workshop and expert facilitation.

There is no cost to join, but to participate you need to have an interest in Continuous Improvement and Enterprise Excellence. If you are interested in registering for the Forum please do email info@shingoforum.org

Join Now

This monthly virtual forum will provide you with a chance to hear from Shingo Facilitators, Examiners and Award-Winners.

  • Benchmarking
  • Sharing ideas & Inspiration
  • Networking (in a fun way – no selling!)
  • Discounts to Best Practice Visits
  • Access to Webinar Recordings & Resources

Guest Speaker: TBC

Hosted By: John Quirke – Shingo Facilitator

SHINGO Forum Virtual Meet-Up

About the visit

The Shingo Forum exists to encouraging the sharing of ideas and inspiration between organizations. This virtual networking group meets monthly and includes a guest speaker; interactive workshop and expert facilitation.

There is no cost to join, but to participate you need to have an interest in Continuous Improvement and Enterprise Excellence. If you are interested in registering for the Forum please do email info@shingoforum.org

Join Now

This monthly virtual forum will provide you with a chance to hear from Shingo Facilitators, Examiners and Award-Winners.

  • Benchmarking
  • Sharing ideas & Inspiration
  • Networking (in a fun way – no selling!)
  • Discounts to Best Practice Visits
  • Access to Webinar Recordings & Resources

Guest Speaker: TBC

Hosted By: John Quirke – Shingo Facilitator

SHINGO Forum Virtual Meet-Up

About the visit

The Shingo Forum exists to encouraging the sharing of ideas and inspiration between organizations. This virtual networking group meets monthly and includes a guest speaker; interactive workshop and expert facilitation.

There is no cost to join, but to participate you need to have an interest in Continuous Improvement and Enterprise Excellence. If you are interested in registering for the Forum please do email info@shingoforum.org

Join Now

This monthly virtual forum will provide you with a chance to hear from Shingo Facilitators, Examiners and Award-Winners.

  • Benchmarking
  • Sharing ideas & Inspiration
  • Networking (in a fun way – no selling!)
  • Discounts to Best Practice Visits
  • Access to Webinar Recordings & Resources

Guest Speaker: TBC

Hosted By: John Quirke – Shingo Facilitator

SHINGO Forum Virtual Meet-Up

About the visit

The Shingo Forum exists to encouraging the sharing of ideas and inspiration between organizations. This virtual networking group meets monthly and includes a guest speaker; interactive workshop and expert facilitation.

There is no cost to join, but to participate you need to have an interest in Continuous Improvement and Enterprise Excellence. If you are interested in registering for the Forum please do email info@shingoforum.org

Join Now

This monthly virtual forum will provide you with a chance to hear from Shingo Facilitators, Examiners and Award-Winners.

  • Benchmarking
  • Sharing ideas & Inspiration
  • Networking (in a fun way – no selling!)
  • Discounts to Best Practice Visits
  • Access to Webinar Recordings & Resources

Guest Speaker: TBC

Hosted By: John Quirke – Shingo Facilitator