Why Industrial Companies Should Avoid Building In-House Training Programs for Lean Training

Why Industrial Companies Should Avoid Building In-House Training Programs for Lean Training

In the fast-paced world of industrial operations, training programs are essential for maintaining a competitive edge. Operational excellence principles like Lean, Six Sigma, and Kaizen have become critical components of success. However, when it comes to training staff in these methodologies, some companies attempt to build their own programs from scratch.

While the intention is noble, creating in-house training programs often proves to be an inefficient, costly, and distracting approach—especially when external resources already offer high-quality, cost-effective solutions. Let’s explore why industrial companies should focus on leveraging external Lean training programs instead of reinventing the wheel.

The Hidden Costs of In-House Training Programs

At first glance, developing an in-house Lean training program may seem like a practical solution. After all, who knows the company's operations better than internal teams? However, the hidden costs of this approach often outweigh its perceived benefits.

1. Development Costs:

   • Designing a comprehensive Lean training program requires significant time and expertise. Companies need to allocate skilled professionals to create content, develop simulations, and design learning materials. These resources are not free and often come at the expense of core operational goals.
   • Investing in training tools, software, and platforms further drives up costs.

2. Implementation Costs:

   • Delivering training requires skilled facilitators who understand Lean principles and can effectively teach them. Training trainers themselves is another added expense.
   • Hands-on components, a hallmark of effective Lean learning, necessitate investment in physical or virtual environments for practice.

3. Maintenance Costs:

   • Lean principles evolve as industries adopt new technologies and practices. Updating in-house training materials to remain current becomes an ongoing burden.

The Challenges of In-House Lean Training Programs

In-house programs not only drain resources but also present unique challenges that can hinder their effectiveness:

• Lack of Expertise: Developing a program aligned with Lean's nuanced principles requires mastery of methodologies like value stream mapping, waste reduction, and continuous improvement. Without external expertise, internal trainers may overlook critical components or deliver inconsistent training.
• Resource Allocation: Redirecting top talent from operational roles to training development diminishes productivity and can lead to opportunity costs. Employees skilled in Lean practices should focus on applying these principles, not teaching them.
• Risk of Obsolescence: The speed of industrial innovation means that training programs must constantly adapt to new tools and processes. Keeping in-house programs up-to-date can be both costly and time-intensive.

The Advantages of External Lean Training Programs

Instead of spending valuable resources building an in-house Lean training program, industrial companies can benefit significantly from leveraging external providers. Here’s why:

1. Cost-Effectiveness:

   • Pre-developed Lean training programs from established providers cost a fraction of what it takes to build an in-house equivalent. Organizations only pay for what they need, avoiding the sunk costs of development and maintenance.

2. Access to Expertise:

   • External training providers employ industry experts who live and breathe Lean principles. These trainers bring years of experience and can adapt content to the company’s unique challenges.
   • Many programs also provide certifications that boost employee morale and credibility.

3. Scalability:

   • External programs can be tailored to large or small teams, offering the flexibility to scale training efforts as needed. Companies can quickly onboard new employees or roll out advanced training for senior staff without additional development time.

4. Reduced Administrative Burden:

   • Training providers handle logistics, from scheduling sessions to updating materials with the latest Lean methodologies. This allows companies to focus on operational priorities.

5. Focus on Core Operations:

   • By outsourcing Lean training, companies can keep their internal experts focused on implementing Lean principles to improve processes and reduce waste.

Case Study: External Lean Training in Action

Consider the example of a mid-sized manufacturing company that attempted to develop its own Lean training program. Initially, the team allocated senior managers to design the curriculum, expecting it to be completed within six months. However, as the managers struggled to balance their training responsibilities with day-to-day operations, the project dragged on for over a year. The resulting program was inconsistent, lacked engagement, and failed to deliver measurable results.

After switching to an external Lean training provider, the company saw immediate improvements. The external program offered hands-on simulations, clear certification pathways, and a proven track record. Employees completed their training in weeks rather than months, and the company saved over 40% compared to its initial in-house attempt. Most importantly, the trained staff quickly applied Lean tools to reduce production lead times by 15%.

Key Considerations When Choosing External Training Providers

When evaluating external Lean training programs, companies should consider:

• Alignment with Goals: Does the program address your company’s specific Lean challenges?
• Proven Expertise: Is the provider experienced in your industry?
• Customization Options: Can the program be tailored to your company’s operations?
• Ongoing Support: Will the provider offer continuous updates and resources as Lean practices evolve?

Conclusion

While the appeal of developing in-house training programs is understandable, the reality is that it often costs more, delivers less, and diverts resources from core business priorities. External Lean training programs, on the other hand, provide cost-effective, expert-driven solutions that empower teams to achieve operational excellence without the headache of starting from scratch.

If your company is looking to adopt or enhance its Lean practices, consider outsourcing your training needs. You’ll save time, reduce costs, and ensure your team is equipped with the tools they need to drive continuous improvement. Let the experts handle the training, so your team can focus on what they do best: running a world-class operation.