Lean Flow Line Design Workshop

How to Design – and Run – the World’s Most Efficient Facilities

The Need

Right there in your office, you have at least one book on Lean. It’s probably a good read, and fundamentally correct. But it is not a comprehensive manual. After all, a good book can discuss someone else’s efficient business. No book can show you exactly how to establish your business as one of the world’s most efficient facilities.

Just what constitutes the world’s most efficient facility? One in which:

  • Total product lead time represents flow – the sum of its critical-path value-add time, with minimal delay, wait or queue.
  • Inventory is lean – in just the right places, in the right quantities, at the right times – and balanced to achieve both your inventory KPIs and your customer-service targets.
  • Quality occurs at the point where work is done, and not through post-inspection yield and rework.
  • The facility itself is a showcase for customer visits, with visual, tangible flow – products move, people “flex” to where they are most productive, “a place for everything and everything in its place.”
  • The facility’s financial performance confirms its efficiency – quality costs are low, productivity is high, short lead times provide increased market share and/or pricing premiums, inventory turns are double-digit.

Your competitors have those books, and they may be doing more than just reading them. For your business to become one of the world’s most efficient facilities - more efficient than your competitors – you need person-to-person Lean Flow education, conducted by an experienced, real-world instructor.

You need our FlowVision Lean Flow Line Design Workshop. We are experts – we have the mathematical tools to model Lean Flow. We implement it, and we teach it. Our Line Design Workshop equips your management and Lean Flow implementation team members with step-by-step techniques and experience, so they are thoroughly prepared to make your facility one of the world’s most efficient.

The Approach

Our Line Design Workshop is not a lecture or seminar. It is hands-on – the students actually apply Lean Flow techniques, as they learn them, to implement Lean Flow in a portable workshop facility.

The Workshop uses an effective teaching method: First, students see a Lean Flow technique. Then, students and instructor discuss the technique. Next, the students apply the technique, hands-on. Finally, the instructor and students’ conceptually apply the technique to the students’ processes, products and facilities.

Using this method, the Line Design Workshop presents all the calculations – the mathematical basis for FlowVision Lean Flow. It defines clearly all the data that goes into the calculations.

This Workshop is more than foundational math and data. It provides, in every student’s accompanying workbook, every detail in our step-by-step approach to Line Design. It prepares your leadership and systems for the Lean Flow change: supporting, managing and sustaining your Lean Flow implementation. It prepares your production experts to unleash their knowledge and talents. It unifies your Lean Flow implementation team in techniques, tools and terminology.

The Benefits

The Line Design Workshop enables you and your team to begin and maintain a quick, steady pace during your Lean Flow implementation. It eliminates the potential for confusion in terminology, disagreements over techniques and order of implementation priority. It equips your team to use facts, not emotion, and convert your business to one of the world’s most efficient facilities.

Here are typical “most efficient facility” results:

  • Production lead time and work-in-process inventory reduced by 75%
  • Finished goods reduced by 50%
  • On-time delivery 90% or higher, achieving targets
  • Workforce productivity up 12%
  • First-full-year return on investment from 4-to-1 to 10-to-1
  • Cash goes up as inventory goes down
  • Floor space is cleared and available for future growth
  • Working capital and other financial measures reflect the results

The Costs

Our pricing varies, based on the nature of your production processes, the number of students and whether the Workshop is private or public. FlowVision provides scalable solutions for any size business. A typical investment made in Lean Flow solutions will provide a 4-to-1 to 10-to-1 payback within the first year of implementation. Our Business Assessment details all benefits and costs.

Contact us

Call FlowVision at +1.970.262.6536 or contact us to enroll in our Lean Flow Line Design Workshop.

Lean Flow Line Design Workshop


FlowVision's workshop provided the perfect combination of theory and practical application of the Lean Flow methodology, minus the sales and propaganda I've seen in similar classes. Our cross-functional team left the class energized about the potential of Lean Flow and excited to implement the tools internally. Having attended Lean Flow training from other companies, I know that FlowVision accomplished more in 3-1/2 days than others can in 7 days. This class provided a firm foundation to build upon as we enter the implementation phase.

Dave Arnold
R2 Technology