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J.H. Berk and Associates

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Manufacturing Leadership Training

Manufacturing enterprises frequently thrust competent technicians into leadership positions with no preparation or supervisory training.  Manufacturing lead personnel and supervisors want to do a good job, but they frequently move into their new assignments without the tools required for leadership success.

Manufacturing Leadership Training is a 6-class, 24-hour program of instruction focused on developing manufacturing leadership and supervision skills.  The Manufacturing Leadership Training program will provide manufacturing supervisors with the ability to:

  • Understand supervisory responsibilities and authority.

  • Understand how manufacturing enterprises operate.

  • Develop and use leadership skills to motivate their teams.

  • Communicate effectively with subordinates, peers, and superiors.

  • Identify and resolve conflicts.

  • Understand and use productivity measurement techniques.

  • Understand basic quality management philosophies.

  • Use problem solving techniques to improve manufacturing processes.

  • Recognize and address subordinate training needs.

  • Understand and fulfill the requirements of supervisory and lead person assignments.

The Manufacturing Leadership Training program is presented in six weekly on-site sessions.  The program can also be presented in a three-day format.  The training approach includes presentation, interactive discussion, and training exercises.  Special materials are included for those operating in a bargaining unit environment to assure that Unions are part of the solution, and not part of the problem.  Training is tailored to meet the unique needs of each client.

Materials

  • A Handbook for First Time Supervisors: Managing Effectively

  • Manufacturing Leadership Training (a set of approximately 200 presentation charts and case study materials), ManufacturingTraining.com Seminars.

Who Should Attend

Manufacturing, Quality Assurance, and Repair Center supervisors, lead personnel, foremen, and others in manufacturing or production-related related leadership positions should attend this training.

Manufacturing Leadership Training Syllabus

  • Class 1: Basic Leadership Skills.  The nature of the manufacturing enterprise.  Leadership, supervision, and management.  The organizational culture.  The nature of the lead person assignment.  Lead person responsibilities and authorities discussion.  Power and influence.  Situational leadership.  Motivators and demotivators.  Identifying and understanding conflict.  Eliminating blame, fear, and intimidation.  Class exercise.  Reading assignment.

  • Class 2: Being a Leader.   Basic leadperson responsibilities.  Relevant company procedures and job descriptions.  Using manufacturing instructions, visual standards, and inspection checklists.  Planning and assigning work.  Productivity.  Identifying and correcting productivity detractors.  Assessing work from quality and productivity perspectives.  Providing feedback to subordinates.  Recognizing and rewarding superior performance. Production scheduling.  Maintaining a clean and orderly working environment.  Knowing when to ask for help.  Class exercise.  Reading assignment.

  • Class 3: Building In Quality.  Quality assurance concepts.  Prevention versus detection.  The inspection function.  Lead person responsibility with respect to assuring a quality product.  Establishing, maintaining, and enforcing standards.  Quality measurement and reporting.  Field data.  Pareto analysis.  Identifying and communicating problems.  Problem solving and the four-step problem solving approach.  Lead person responsibilities related to manufacturing instructions, tooling, and design.  Developing corrective actions.  Monitoring corrective action effectiveness.  Class exercise.  Reading assignment.

  • Class 4:  Production Control and Basic MRP II Concepts.  The nature of the production control challenge.  Planning functions.  Shop paperwork.  Basic MRP II operating principles.   The need for timely transactions.  Dispatch reports.  Job priorities.  Work order initiation and completion.  Dispatch report adherence.  MRP improvement opportunities.  Monitoring dispatch report criticality.  Knowing when to ask for help.  Discussion on MRP II issues and challenges.  Class exercise.  Reading assignment.

  • Class 5: Training.  Lead person and supervisor training responsibilities.  Recognizing job-specific success factors.  Training newly-assigned personnel.  Refresher training.  Monitoring employee performance.  Recognizing training needs.  How to request training assistance.  Recommending employees for training.  Lead person requirements and expectations.  Company culture discussion continuation and the role of the lead person in shaping the culture. Class exercise.  Reading assignment.

  • Class 6: Standards, Productivity, and Course Wrap-Up.  Productivity defined.  Manufacturing standards concepts.  Understanding standards utilization.  Identifying productivity detractors.  Lead person and supervisor responsibilities for addressing productivity shortfalls.  Options for recognizing and rewarding superior productivity.  Productivity challenges.  Efficiency and utilization.  Course review.  Course critique.  Final examination.  

 
 

The above training can be customized to meet your requirements.

Need a guest speaker for an important luncheon or dinner meeting?  Please contact us.

Any questions?  Please call us at 909 204 9984 or contact us via e-mail.
An unending focus on cost reduction is what makes businesses survive and thrive in good times and bad.  Our newest book, Cost Reduction and Optimization for Manufacturing and Industrial Companies, was published in January 2009 by Scrivener Publishing and Wiley.  This is a hands-on, no baloney, rapid road map approach for any organization interested in identifying and acting on cost reduction opportunities.  The book focuses on design, process, supplier, and overhead areas.   In addition to providing roadmaps in each area, this book identifies the risks (and actions to control risk) for each recommendation. As an added feature, Excel templates for the quantitative assessment techniques included with this book can be downloaded here.  (If you need help with this template, just give us a call at 909 204 9984.)
One of our key training areas (and the one we built the business on) is failure analysis.  We know what it's like when recurring failures add cost to the operation and you have to find the right fix quickly.   We also know what it's like when a failure shuts the operation down or prevents clients from using your product.  

ASM International published our latest work, Systems Failure Analysis, in December 2009, and you can order a copy here.  This is a great book based on actual experience in manufacturing environments, with a focus on finding and fixing root causes of complex systems failures.   Our Failure Analysis and Root Cause Analysis training programs use the approaches and technologies described in Systems Failure Analysis because they work, as many satisfied clients will attest.

Quality Management for the Technology Sector focuses on implementing quality management techniques with proven track records.  This 1-day seminar focuses on quality measurement, root cause corrective action techniques (including FMEA, FTA, and SFA), defining customer expectations (including QFD), using statistical techniques (including SPC and DOE), supplier teaming, and the latest quality standards (including ISO 9001:2000).  The program is based on Quality Management for the Technology Sector (Butterworth-Heinemann, 2002), our hands-on, practical guide to implementing effective quality management tools.

I would highly recommend this book not just to quality assurance professionals, but to professionals in all disciplines. - John W. Gozza, Quality Assurance Manager, Composite Structures LLC

Have a new management assignment, or know someone who recently was promoted into one?  Check out our book that provides guidance for new managers, A Handbook for First Time Managers.

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