Client Site Education

Safety Bootcamp

Our 5-Phase Journey to world-class safety has been practiced and proven by Milliken & Company teams for more than two decades. Acquire the practical skills and methodologies to support your organization’s change readiness and discover how to engage your employees. 

Executive Safety Bootcamp

1 Day Comprehensive Workshop on Safety Systems and Processes. An accelerated version of our 2 Day Safety Bootcamp for your organization’s leadership, attendees will learn practical skills and methodologies to support change readiness and engage employees. 

Continuous Skills Development Basics

2 Day Bootcamp on The Importance of Standardized Training Process. Designed to build a general understanding of the importance of a standardized training process to ensure associates are doing the right things, the right way, every single time.  Understand the basics of how a standardized training process can be developed at your location  to improve multiple manufacturing metrics: safety, quality, cost, delivery, OEE, process reliability, and increases morale & associate satisfaction. 

Incident Investigation Workshop

2 Day Comprehensive Workshop on Incident Investigation. Understand the critical components of an incident investigation process to be used for all injuries or near-misses and compare to your organizations current structure.  Identify strengths and opportunities for improvement and aggressively work to develop a plan to close any gaps. 

Behavior Based Safety

An in-Depth 2 Day Comprehensive Workshop on Behavior Based Safety. Deep dive to understand the basics of a behavioral based safety process and define the components of the ABC model.  Framework of how to utilize the concepts of consequences and begin implementing positive reinforcers in your daily activities.  

5S Excellence Workshop

3 Day Workshop Focused on Creating the Foundation and Desire for Workplace Organization. A place for everything, and everything in its place. This is a basic principle that everyone knows but are not effectively practiced. Manufacturing facilities often lose sight of this principles.  Learn the concepts of creating solutions to organizational problems, find lost space, and learn to sustain the process.  Work through the process in a "Model Area" to learn and apply the concepts.  At the end of the session, the Model Area will be in a 5S Level 5 state.

Financial Breakthroughs

2 Day Workshop on How to Reduce Manufacturing Costs Through Zero Loss Thinking, Waste Removal, and Employee Engagement. Milliken’s approach to cost reduction has been developed over the past three decades after benchmarking best practices around the world. Learn this simple yet effective, replicable approach for breakthrough improvements involving all associates.

Lean Bootcamp with Value Stream Map Creation

5 Day Bootcamp on How to Reduce Manufacturing Costs Through Zero Loss Thinking, Waste Removal, and Employee Engagement.  This workshop applies learnings from Milliken’s lean journey to your company by applying concepts such as the eight wastes, value stream mapping, SMED, and standard work. Fun games create an interactive environment for learning. Application and creation of a Value Stream Map – Current and Future State – to solidify learnings and provide a tool for the location to drive improvements moving forward.

Zero Loss Workshop

2 Day Workshop on the Performance System Foundation. This overview workshop focuses on teaching your organization’s leadership the fundamentals of Zero Loss Thinking and the development of their loss names, definitions and calculations. Attendees also learn about establishing and analyzing losses to drive projects.

Hoshin Planning (Strategy Deployment)

1 ½ Day Class on Creating a Strategic Action Plan for Change. Apply the concepts of Hoshin Planning to drive breakthrough improvements within your organization. Through working sessions, this workshop develops the business X-Matrix, action plans, and a process to monitor projects to achieve Hoshin goals.

SMED - Single Minute Exchange of Dies

2 Day Workshop Targeted to Reduce Changeover Time. As processes must be more flexible to meet customer’s needs, we must be able to run smaller batch sizes and changeover more frequently. Apply the SMED methodology to identify and eliminate waste in the changeover process. This workshop is an interactive and hands-on kaizen focused event.

5S Excellence Workshop

(COMBINE WITH OTHER "5S Excellence Workshop" Page in Safety)
3 Day Workshop Focused on Creating the Foundation and Desire for Workplace Organization. "A place for everything, and everything in its place."  We learned that at a young age.  Unfortunately, factories become a place where that is not practiced often.  Learn the concepts of creating solutions to organizational problems, find lost space, and learn to sustain the process.  Work through the process in a "Model Area" to learn and apply the concepts.  At the end of the session, the Model Area will be in a 5S Level 5 state.

Basic Focused Improvement

5 Day Bootcamp on How to Create an Environment of Problem Solving. Focused Improvement Basics is designed to build general understanding of the Focused Improvement project methodology, DMAIC and rudimentary data-analysis and problem-solving capability.   Through classroom instruction and hands-on activities, participants develop the ability to apply the Focused Improvement methodology in their roles.  

Quality Management Basics

3 Day Bootcamp on The Importance of In-Depth Equipment Knowledge. Designed to build a general understanding of a systematic methodology to achieve zero quality defects (not just fewer defects) by seeking out, identifying, and eliminating root causes of ALL defects. Provides a framework by outlining project implementation steps and activities.  

New Product Development Basics

3 Day Bootcamp on The Importance of Effectively Bringing New Products to Market. New Product Development Basics is designed to provide a general understanding of the importance to establish linkage between business & manufacturing goals and objectives to ensure the company has a standardized, repeatable process for new product introductions.  The course outlines the use of project management methodologies to manage time, money and people resources while reducing the cycle-time to introduce new products.  

Early Equipment Management Basics

3 Day Bootcamp on The Importance of Starting Up New Equipment Safely, Efficiently and Effectively. Designed to build a general understanding of how to coordinate new equipment start-up activities with the business and other critical support functions, to successfully start-up new equipment within the desired targets, and to ensure that new equipment is manufacturing “friendly”. The course outlines the use of project management methodologies to manage time, money and people resources while reducing the cycle-time to introduce new products.  

Maturity Assessment

2-3 Day Assessment to Compare Current State Against Fully Mature System. The purpose of a Maturing Assessment is to compare the current state condition of the Site Performance Excellence process against a fully mature system.  The assessment addresses structure, depth of application and results.  Features a series of interview sessions to gather information and uses the results to score the site, identifying strengths and gaps.

World Class Training on Maintenance and Reliability Teams

A 2 Day Collaborative Approach to Reliability for Improved Manufacturing Performance. Shelve theoretical models and learn Milliken’s effective processes through practical classroom instruction, hands-on activities, and real life manufacturing examples. In this class, you will learn Milliken’s approach to autonomous and planned maintenance.

Failure and Root Cause Analysis Workshop

A 3 Day Deep Dive into Effective Failure and Root Cause Analysis. Prevention of unplanned downtime is the secret to success.  Work with skilled practitioners to understand how to effectively collect and analyze data to determine the cause of a failure and identify countermeasures to prevent future occurrence.   Review tools and templates to aid in this problem-solving methodology and understand how to integrate into your daily life. 

Leadership Development

An In-Depth 2 Day Workshop on Leading & Supporting Your Cultural Change. Create the leadership mindsets and behaviors necessary to be a High-performance leader as driving force to make the transformation in the whole plant.  We will leverage the process described in The Leadership Challenge by James M. Kouzes and Barry Z. Posner to develop a new paradigm on what constitutes Leadership.  Interactive session that will identify specific behaviors to practice, identify specific situations we should be part of, demonstrate these behaviors, and achieve the transformation using the Focused Improvement methodology of DMAIC. 

Leadership Pre-Implementation Bootcamp

2 Day Bootcamp to Get Leadership Ready for Implementation. This overview workshop focuses on educating and aligning key Leadership teams around the technical aspects of the Performance System. In order for the Performance System to be successful, Leadership must be prepared and ahead of the curve. Simply put, Leadership must know what is coming before the line associates receive their training. 

Leading Change in an Operations Environment

1½ Day Workshop Focused on Learning How to Lead Change. This highly interactive workshop focuses on the personal skills necessary to create change and transform your business effectively. Exercises and discussion center on behaviors associated with personal leadership, innovation, customer focus, teamwork, communications and trust. You’ll also learn the key ingredients that helped Milliken adapt and react in increasingly competitive markets. 

Team Leading Skills

1 Day Workshop. Your Performance System will leverage numerous types of teams. The various types will include Safety teams, project teams, production teams, equipment teams, and maintenance teams. In a Performance System environment, all levels of associates are utilized to lead teams, so it is imperative that they understand how to lead a team. This course focuses on the characteristics necessary to lead a team, how a team should function, and other team fundamentals. 

Critical Skills for Successful Supervisors

3  Day Workshop targeted for the changing role of Supervisors. Today’s highly competitive business environment demands that individuals and organizations perform at higher levels and with greater speed than ever before.  Supervisors must learn, understand, share and determine what it takes to effectively lead others.  The focus of the workshop is on effective communication, holding your team members accountable, addressing performance issues, and handling conflict.

Daily Management System

1 to 2 Day Class to Understand the Importance of Structure for Daily Operations. Most clients we work with begin their Performance System journey in a highly reactive state of firefighting. When Leadership and Line Associates are firefighting, improvement work is not occurring.  The target of the Daily Management System is to provide engagement, stability, and structure to the way the plant does its daily work. Once stability is established, there will be time to complete improvement work and interact with the Pillars at an optimal level.

Auditing Skills

Sustainability is a critical challenge to a Performance System. One of the primary tools employed to achieve sustainability and engagement of associates is auditing. This course focuses on the principles and techniques of auditing. 

Teach the Teacher

1 Day Workshop Targeting full time and on the job instructors. When education is delivered in different ways, variation in execution can enter the job.  This workshop focuses on a proven model of workplace education that is a standard method and provides solid results in less time than typical methods.

Practitioner Certification

3 to 6 Month Process. The Practitioner Certification process is targeted at preparing your identified internal Practitioners for their role in the sustainability plan of the Performance System. The Practitioner Certification is composed of 4 levels: Implementation Participation, Technical Pillar Certification, Instructor and Coaching Certification, and Practitioner Certification.