About Us
What We Do
TSD LLC is a specialized lean and six sigma consulting and training firm that helps companies achieve operational excellence by assisting them not only in training, but also in the implementation of World Class Manufacturing systems. TSD utilizes advanced value stream mapping techniques to develop the blueprint that will be utilized to create Visual Flow throughout the value stream. Visual flow enables employees at all levels to see the flow of value to the customer. Once implemented, even someone unfamiliar with the process will be able to determine if the value stream is meeting the customer demand.
But just seeing the flow is not enough. When the value stream is not meeting your customer’s demand, someone has to correct the issue that is disrupting flow. In most companies, that someone is a Supervisor, Engineer, Manager, etc. With TSD’s visual flow system, we provide the value stream operators with the tools to correct flow disruptions. This creates an immune system for your value stream that restores the flow without having to go up the chain of command.
Contact TSD today to see how we can assist you in achieving visual flow!
Executive's Summary
Tim Lieffring
President
- Founder of TSD LLC, a Training and Implementation Company Specializing in Operational Excellence, Lean, Six Sigma, and Total Productive Maintenance
- An Operations Executive in the automotive, appliance, plastics, and packaging industries that has proven process improvement abilities adding millions of dollars to the bottom line
- 30 plus years of experience in Lean, TPM, Six Sigma, and Operational Excellence methodologies that started as an employee of Sony Corporation in the 1980’s
- Recognized as a trusted advisor who uses excellent leadership skills to drive significant process improvements in the most difficult operating environments
- Certified as a Lean Six Sigma Master Black Belt, Design for Six Sigma Black Belt, and a TPM facilitator
Specialization and Skills
- Advanced value stream design
- Hands-on implementation processes
- Mentors to all levels of an organization
- Cultural change agents
- Total Productive Maintenance
- Kaizen Facilitation
- Six Sigma Project Management and Execution
Design Workshops
Value Stream Mapping
Every business process, whether manufacturing or a service, has a series of both value added and non-value added steps that must be performed to deliver the product to the customer. Value stream mapping is a visual tool that allows us to see the information and product flow through the system.
TSD utilizes a five-step process to design a lean future state value stream that is the foundation of Visual Flow. Along the way, improvements that are necessary to achieve the lean future state design are identified. This becomes our blueprint to achieving visual flow.
Class Objectives:
- Teach the lean fundamentals
- Go to the production floor to Value Stream Map the current state
- Learn the guidelines to make a Value Stream lean
- Learn how to design your future state Value Stream
- Develop an implementation plan to make the future state a reality
The participants will learn the mapping techniques through a class room simulation and then will apply the techniques on your value streams!
3P
3P (Production, Preparation, Process) is a tool used to develop the value stream and/or facility layout. Once the future state design is completed, we often find that the current layout will not support the design. TSD will lead your team through the development of layout options that will be evaluated, against criteria developed by the team, to achieve the optimum design. Once the design is complete, the team will mock-up the layout to identify and eliminate issues before they have an opportunity to disrupt production.
Class Objectives:
- Create designs and layouts that maximize flow and minimize waste
- Maximize our ability to meet customer demand with the minimum amount of resources (capital, floor-space, etc.) possible
- Make flow visual so the employees can see normal vs. abnormal flow
- Solve problems or address improvement opportunities with a particular layout before we begin moving equipment
Workstation Design
Participants learn how to design a workstation to provide the optimum flow. Whether you are linking multiple current state processes into a single future state continuous flow cell or you need to design a better single-step workstation, this class teaches participants how to create flow using the following techniques:
- Cell layout
- Operator balancing
- Machine balancing
- Workplace organization
- Ergonomic design
- Workstation mock-up
Class Objectives:
- Introduce a process to create flow in cells
- Understand the system design concepts
- Apply what we have learned on the floor
- Measure the improvements
FIFO Design
When you can’t use continuous flow, the next best option is FIFO. During the workshop, students will first complete the classroom training and then complete detailed designs and implementation plans for the FIFO connections identified in your future state value stream map.
Class Objectives:
- Understand why, when, where and how to employ FIFO lanes for managing flow and inventory
- Learn how FIFO can help facilitate flow
- Understand key concepts and be able to perform calculations for FIFO lane sizing
- Learn when to use FIFO versus when to use supermarkets
- Learn the keys to success for standard work and continuous improvement with respect to FIFO lane usage
Pull System Design
When you can’t use continuous flow or FIFO, the final option is Pull. During the workshop, students will first complete the classroom training and then complete detailed designs and implementation plans for the supermarkets (pull systems) identified in your future state value stream map.
Class Objectives:
- Learn what a pull system is
- Understand how a pull system works
- Know how to create a pull system
- Learn how to analyze inventory levels and calculate the supermarket size
- Learn the physical attributes of pull systems
Lean Foundation Workshops
5S
Proper workplace organization and identification will improve safety, decrease downtime, and improve employee morale. 5S is not only a system to improve the workplace organization, but it also provides a methodology to sustain the improvement.
- Sort - Remove unneeded items from the workplace
- Straighten - Define where the needed items will be stored
- Shine - Clean the workplace
- Standardize - Make the improved work area the standard
- Sustain - Make a habit of maintaining the improved work environment
Class Objectives:
- Introduce 5S
- Demonstrate the benefits of 5S
- Learn how to implement 5S
- Implement the first three steps at a workstation in your plant
Quick Changeover
The increasingly competitive global economy and heightened customer expectations have intensified the pressures on manufacturers to grow their flexibility and shorten lead times. To do this, it’s critical to reduce lot sizes by reducing EPEI (Every Part Every Interval) as a smaller EPEI will result in greater capability to deliver products on time.
After receiving quick changeover training, participants will video record a changeover on your production floor, analyze the video, and develop an improved changeover process.
Class Objectives:
- Understand how quick changeovers improve value stream flow
- Understand the key concepts related to quick changeover
- Learn the principles of quick changeover
- Learn to apply quick changeover tools using a disciplined, visual process of documentation and improvement.
Total Productive Maintenance
As we strive to create lean value steams with increased flow, it is critical that we have reliable equipment. Unreliable equipment in value streams will force companies to increase inventories in FIFO lanes and supermarkets, resulting in longer lead times. To improve reliability, operators and maintenance need to collaborate to restore the equipment to the OEM state using TPM (Total Productive Maintenance).
TPM ensures that both the operators and maintenance personnel are able to see abnormal equipment conditions prior to breaking down. Fixing abnormal conditions before equipment failure involves operators performing autonomous maintenance and maintenance personnel performing planned maintenance.
Class Objectives:
- Understand the purpose of TPM
- Learn the four TPM Steps
- Implement actions to progress to OEM or better specs
- Position teams to complete actions in short-order via an implementation event
Kaizen
Companies have been doing kaizens for years, yet many have had mixed or disappointing results. When lean programs that are heavily based on kaizen fail to grow the business, it is typically because they are using kaizen to make point improvements rather than targeting value stream level problems that are disrupting the overall flow. The Kaizen training course will teach participants how to select kaizen events base on value stream level improvements, how to plan and execute the kaizen, and what needs to be done to follow up after the event.
Class Objectives:
- Understand kaizens, what they are, why they are used, and how they can be deployed for maximum effectiveness
- Learn the kaizen process: planning, event, and follow-up
- Learn how to select team members for kaizen events
Standard Work
It doesn’t matter if you are a manufacturer or a service provider, you have work processes and all effective work processes need Standard Work. Yet this simple concept is one that is lacking in many businesses. Participants will learn how to define standard work using time studies, standard work sheets, standard work combination sheets, and standard work charts. Next, the students will learn how to write effective standard work and how to effectively train your personnel.
Class Objectives:
- Learn to define the work elements that make up tasks and balance the elements between operators
- Learn the elements that make up effective standard work
- Understand what process level standard work and value stream level standard work are
- Learn how to train employees using Training Within Industry (TWI) methods
Six Sigma Project Management and Execution
Project Management and Execution
Not all value stream problems can be addressed using lean tools. Often, process variation, productivity, and downtime issues require six sigma solutions. TSD can provide experienced black belts and master black belts to work with your team to manage and execute six sigma improvement projects.
TSD uses a process-focused approach to improvement while guiding you through the intricacies of delivering a successful six sigma project. Combining extensive manufacturing experience with the proven DMAIC process, enables TSD to deliver high value solutions for your business.
DMAIC Process:
- Define – Utilize scoping and definition tools to define and articulate the business problem, identify the project goals, select the project team, and develop the high-level timing
- Measure – Focuses on determining the baseline performance, learning about the process output (Y), and determining the capability of the measurement systems to effectively measure the process inputs and outputs
- Analyze – Identify and test the potential critical process inputs (Xs) to identify the root causes of the defect: Y = f(x1, x2, Xn)
- Improve – Identify, validate, and implement the best problem solutions
- Control – Ensure that the gains from the Improve phase are sustained through the development and execution of a detailed project control plan