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763-533-8239
ma@mfrall.com
760-418-4694

6233 Fernbrook Lane N
Maple Grove, MN 55311
Current Events

Generate Cash and Contain Costs
Monthly Educational Program on July 9, 2009 - 7:30 am - 9:30 a.m.
Dunwoody Technical College

Join us and learn how to shorten your order to cash cycle, reduce on-hand inventory while improving customer service, streamline processes, improve margins and control many operating costs.

Simplify and make better decisions by presenting and viewing your financial information differently. You may be passing on profitable opportunities. Support, don't stall, growth throughout your company.

Reward your employees for a job well done - invite them to an educational program.




Design for Manufacturability
Workshop on July 23, 2009 - 1:00 - 5:00 pm
Maple Grove Community Center

Break down the "wall" that stands between Design and Manufacturing.

Learn how to design components and assemblies that will reduce the risk of non-conformance to the established specifications and how you can introduce this concept into your company.

In-house sessions available-call 763-383-9445




Lean Product Development 2P
Workshop on July 23, 2009 - 8:00 a.m. - 12 noon
Maple Grove Community Center

Do you want to improve your product development time and designs as well as product costs and processes?

This interactive hands-on workshop teaches a facilitated team-based design process that uses simple tools combined with the creativity of people to achieve breakthroughs that meet the needs of all stakeholders.

In-house sessions available-call 763-383-9445




Design for 6 Sigma, DFSS
Workshop on July 28, 2009 - 8:30 am - 4:30 pm
Maple Grove Community Center

Design for 6 Sigma (DFSS) a two-day class, focuses on designing the product or process “right” the first time. The first workshop, “Capturing Customer Design Requirements” will teach critical success factors in capturing customer needs and perceptions and translating them into customer requirements and solution concepts. The second workshop, “Selecting a Design Solution Concept” will teach techniques to select critical parameters and track a solution that meets customer needs. All will participate in interactive discussions and exercises.

Capturing Customer Design Requirements
When: July 28, 8:30 a.m. - 4:30 p.m.
Where: Maple Grove Community Center

Selecting a Design Solution Concept
When: August 19, 8:30 a.m. - 4:30 p.m.
Where: Maple Grove Community Center




Leaders Standard Work
Workshop on July 29, 2009 - 8:30 am - 4:30 pm
The Reserve - Plymouth

Standard work for leaders is the engine that drives the lean management system and is crucial to any successful lean implementation.

Learn how to develop leaders standard work appropriate for all levels of the organization. Ensure the standard work is followed and generates results as well as continuous improvement.

In-house sessions available-call 763-383-9445





Intro to 6 Sigma
Workshop on July 30, 2009 - 1:00 pm - 5:00 pm
Maple Grove Community Center

Great Workshop for Teams!

All attendees will participate in interactive exercises that demonstrate, in a practical manner, the application of 6 Sigma principles and tools. The application of these improvement techniques applies equally to the plant or office, manufacturing or service.

In-house sessions available-call 763-383-9445




Continuous Improvement in a Regulated Environment
on July 30, 2009 - 8:00 - 10:30 am
Beckman Coulter - Chaska, MN

For Medical Device Manufacturers and Suppliers

Implementing Lean improvements helps to eliminate waste, clarifies processes and minimizes opportunity for mistakes. Just what the FDA wants, but how do you meet all those regulations? Hear from Medical Device peers who have made the leap to a Lean operation and are reaping the benefits of Lean while meeting strict GMP requirements successfully and compliantly.

Certificates of attendance will be provided to be used towards CEUs and contact hours.




Lean Manufacturing Simulation
Workshop on July 30, 2009 - 8:00 a.m. - 12:00 noon
Maple Grove Community Center

Great workshop for teams!

Lean Manufacturing is the most productive, flexible, and highest quality approach to manufacturing - proven by bottom-line results. Attendees participate in an interactive business simulation that demonstrates, in a practical manner, the application of lean principles.

In-house sessions available-call 763-383-9445




Persuasive Coaching & Influencing
Workshop on August 4, 2009 - 8:30 am - 4:30 pm
The Reserve - Plymouth

It takes more than a title and some authority to effectively lead people; ask anyone newly promoted into a leadership role!

This course assists participants with understanding and developing the influence and persuasion skills that make them more effective as team leaders.

In-house sessions available-call 763-383-9445




Kaizen Rapid Improvement
Workshop on August 5, 2009 - 8:30 am - 4:30 pm
Precision Gasket - Training Center

Do you need productivity and cost improvements now?

This workshop will provide the education and experience that is necessary for you to deploy rapid improvement teams at work. Interactive team exercises demonstrate, in a practical manner, the application of Kaizen techniques and principles.

In-house sessions available-call 763-383-9445




Essentials of Leading for Results
Supervisory Training on August 6, 2009 - 1:00 - 5:00 pm
Maple Grove Community Center

Designed specifically for manufacturers . . .
Leadership training for front-line managers, supervisors and team leaders!


Offered as part of the Learning to Lead Supervisory Training Series. Each series of six sessions may be taken sequentially or independently, depending upon experience and needs.

Additional Series: Leading Down New Paths
April 9 - May 14, 2009

Please note: To register for the entire Learning to Lead series go to the Training Series flyer.

In-house sessions available-call 763-383-9445




A3 Thinking Applied to Policy Deployment
Workshop on August 11, 2009 - 1:00 - 5:00 pm
Wooddale Church - Eden Prairie

The A3 thinking process provides structure to policy deployment.

The A3 process allows the organization to reflect on past results and activities in order to establish the new annual plan with associated objectives, projects and risk analysis.

In-house sessions available-call 763-383-9445




Intro to A3 & A3 Policy Deployment- Both
on August 11, 2009 - 8:00 a.m. - 5:00 pm
Wooddale Church

Each workshop can be taken independently or sign up for both and save.

Intro to A3 Improvement Process: As a Lean Tool, A3 reporting addresses the root causes of problems that arise every day at work. When used properly, the A3 process dramatically increases the probability of success.


A3 Thinking Applied to Policy Deployment: The A3 thinking is a proven and powerful approach used by Toyota an many other companies. Policy Deployment enables the organization to focus on the right things to get them done.


This Series includes:

A3 Thinking Applied to Policy Deployment
When: August 11, 2009 from 1:00 to 5:00 pm
Where: Wooddale Church - Eden Prairie.

Intro to the A3 Improvement Process
When: August 11, 2009 from 8:00 a.m. to 12 noon
Where: Wooddale Church - Eden Prairie.



Intro to the A3 Improvement Process
Workshop on August 11, 2009 - 8:00 a.m. - 12 noon
Wooddale Church - Eden Prairie

Solve problems, train others and retain critical knowledge

As a Lean tool, A3 reporting addresses the root causes of problems that arise every day at work. When used properly, the A3 process dramatically increases the probability of success. Leading companies, such as Toyota, to use the A3 report to train engineers, supervisors and managers in a proven and structured problem-solving approach.

In-house secessions are also available-call 763-383-9445.




Lean Office Mini-Series
on August 12, 2009 - 8:30 am - 4:30 pm


Each workshop in this series can be taken independently or sign up for all three and save.

The most untapped improvement opportunities are in the OFFICE! Learn how proven manufacturing improvement processes may be adapted to office systems by attending this 3-course mini-series. These courses must be taken in sequence.

See individual flyers for detailed information regarding these workshops.

In-house sessions available-call 763-383-9445


This Series includes:

Lean Office Simulation
When: August 12, 2009 from 8:30 am to 4:30 pm
Where: Precision Gasket - Training Center.

Office 5S and Visual Management
When: September 2, 2009 from 8:30 am to 4:30 pm
Where: Location to be announced.

Office Process Mapping
When: October 22, 2009 from 8:30 am to 4:30 pm
Where: To be announced.



Lean Office Simulation
Workshop on August 12, 2009 - 8:30 am - 4:30 pm
Precision Gasket - Training Center

This workshop is part of the Lean Office Mini Series. See the Lean Office Mini Series flyer for information on all of our Lean Office workshops.

The most untapped improvement opportunities are in the OFFICE!

Learn how proven manufacturing improvement processes may be adapted to office systems. Participants will experience hands-on learning of lean applications through a simulation exercise.




Is Your Workforce Recovery Ready?
Monthly Educational Program on August 13, 2009 - 7:30 - 9:30 a.m.
Dunwoody Technical College

Make sure key employees and processes are as efficient they can be. Lean tools can eliminate waste now, so that you can absorb new business with your current staff and without unnecessary hiring.

Focus on continuous improvements to keep your workforce engaged with an eye on the future. Train now to emerge stronger than your competition when the recovery comes!

Reward your employees for a job well done - invite them to an educational program.




HR in a Lean Environment
Workshop on August 18, 2009 - 8:00 am - 12 noon
Wooddale Church - Eden Prairie

Learn how your Human Resource practices can Support Lean!

Your HR team can lead and model the lean transformation for the rest of your organization. This class is all about sharing ideas, best practices and learning from our mistakes.

In-house sessions available-call 763-383-9445




Design of Experiments (DOE)
Workshop on August 18, 2009 - 1:00 - 5:00 pm
Wooddale Church - Eden Prairie

Would you like to reduce engineering time and cost with powerful statistical tools?

DOE statistical tools can be applied to improve quality, processes, designs and many Lean and 6 Sigma problems.

In-house sessions available-call 763-383-9445




Lean Material Delivery: Supermarkets, PFEP & Delivery Systems
Workshop on August 25, 2009 - 1:00 pm - 5:00 pm
Maple Grove Community Center

This workshop is part of the Supply Chain Management Mini Series. See Mini Series flyer for details.

Lean material flow can improve the efficiency of the production operator.

This course will introduce you to material movement tools, techniques and metrics and give you the ability to understand what is required in a lean material flow process.

In-house sessions available-call 763-383-9445




Lean Material Replenishment
Workshop on August 25, 2009 - 8:00 am - 12 noon
Maple Grove Community Center

This workshop is part of the Inventory Management Mini Series. See Mini Series flyer for details.


Need to learn how to implement a Lean MRS or improve on a current MRS program?

When setting up a Lean Material Replenishment System (MRS); we will focus on the people, the process, and the sizing. This will decrease inventories, increase material availability, and eliminate many stressful conversations between departments caused by MRP. Attendees participate, in an interactive simulation that demonstrates, in a practical manner, the application of these principles.

In-house sessions available-call 763-383-9445





Inventory Management Mini Series
on August 25, 2009 - 8:00 am - 5:00 pm
Maple Grove Community Center

Each workshop in this series can be taken independently or sign up for both and save.

Lean Material Replenishment This course will assist you in learning how to implement a Lean MRS or how to improve on a current MRS program.
Lean Material Delivery: Supermarkets, PFEP & Delivery Systems: This course will introduce you to material movement tools, techniques and metrics.

In-house sessions available-call 763-383-9445


This Series includes:

Lean Material Replenishment
When: August 25, 2009 from 8:00 am to 12 noon
Where: Maple Grove Community Center.

Lean Material Delivery: Supermarkets, PFEP & Delivery Systems
When: August 25, 2009 from 1:00 pm to 5:00 pm
Where: Maple Grove Community Center.



Policy Deployment, Strategies & Assessments
Workshop on August 27, 2009 - 8:30 am - 4:30 pm
The Reserve - Plymouth

Learn how to assess and develop your lean journey.

Lean implementations are driven by valid performance measures against realistic expectations. Therefore, you need to use a valid baseline of where you are now, an effective strategy on how to get to your goal, and an objective yardstick to measure and communicate improvement progress.

In-house sessions available-call 763-383-9445





Office 5S and Visual Management
Workshop on September 2, 2009 - 8:30 am - 4:30 pm
Location to be announced

Customers, employees and suppliers can tell a well-run office without a narrated tour. The visual clues are everywhere. This workshop is a straight-forward approach that impacts your customer and employee image, productivity and sales.

In-house sessions available-call 763-383-9445




Supply Chain Partners: Selection, Risks & Controls
Workshop on September 8, 2009 - 8:30 am - 4:30 pm
Location to be announced

Risks are an inherent characteristic of depending on supply chains. Learn how to implement robust risk identification and mitigation strategies to create strong supply chain partnerships.

Learn the differences between the traditional transactional relationship with suppliers and what it means to have supply chain partnerships.

In-house sessions available-call 763-383-9445




Voice of the Customer (VOC)
Workshop on September 15, 2009 - 8:30 am - 4:30 pm
The Reserve - Plymouth

Techniques to understand customer needs and perceptions.

This interactive workshop will teach critical success factors in capturing customer needs and perceptions and translating them into customer requirements and solution concepts. When you are able to uncover and balance your multiple customer needs and perceptions, you will then be able to translate them into products that result in profits.

In-house sessions available-call 763-383-9445




6 Sigma Green Belt Certification
Workshop on September 16, 2009 - 8:30 am - 4:30 pm
The Reserve - Plymouth

This Green Belt certification is offered by the Manufacturers Alliance in a 3-part series. The series may also be credited toward Lean/6 Sigma Certification

These courses will allow all attendees to participate in interactive exercises that demonstrate, in a practical manner, the application of basic 6 Sigma principles and tools. The application of these improvement techniques applies equally to the plant or office, whether service or manufacturing. Note: Our instructors are 6 Sigma practitioners with a blend of service and manufacturing backgrounds. Attendees will be required to submit a project in order to receive the certification.

6 Sigma Define & Measure
When: September 16, 8:30 am - 4:30 pm
Where: The Reserve, Plymouth

6 Sigma Analysis
When: October 14, 8:30 am - 4:30 pm
Where: The Reserve, Plymouth

6 Sigma Improvements and Control
When: November 4, 8:30 am - 4:30 pm
Where: The Reserve, Plymouth




Measuring the Right Things
Workshop on September 17, 2009 - 8:00 a.m. - 12 noon
Wooddale Church - Eden Prairie

You get what you measure.

It is critical that what you measure adds to the intended outcome of performance improvements. Learn to measure the right things for the shop and office.

In-house sessions available-call 763-383-9445




Project Monitoring- The Earned Value Method
Workshop on September 17, 2009 - 1:00 pm - 5:00 pm
Wooddale Church - Eden Prairie

This course will outline the fundamentals of Earned Value Analysis, a predictive tool used to monitor project performance.

Learn to: Develop a project plan using work breakdown structures, define objective metrics to determine earned value, track schedule and cost variances, employ forecasting formula to predict a project’s completion date and create simple, visual project status reports using EVA data.

In-house sessions available-call 763-383-9445




Lean Maintenance
Workshop on September 22, 2009 - 8:30 am - 4:30 pm
To be announced

The heat is on to reduce costs and provide consistent results.

Achieve higher reliability from your equipment. Team exercises will demonstrate, in a practical manner, the application of PDM. Proactive planning and predictive maintenance are critical steps for reliable production flow.

In-house sessions available-call 763-383-9445




Value Stream Mapping
Workshop on September 23, 2009 - 8:30 am - 4:30 pm
Location to be announced

Cut lead times . . . React faster . . . Eliminate more waste than ever!
Send your teams to this highly rated, interactive workshop.


Value Stream Mapping is one of the most important tools for Lean Manufacturing. All attendees participate in highly interactive mapping of production and information processes.

In-house sessions available-call 763-383-9445




Overcoming Resistance to Change
Workshop on September 30, 2009 - 8:30 am - 4:30 pm
To be announced

How should dramatic change be led, communicated, supported and its barriers overcome?

This workshop focuses on learning implementation best practices from successful lean transformations. Learn how to overcome resistance and biases to change.

In-house sessions available-call 763-383-9445




Failure Mode and Effects Analysis (FMEA)
Workshop on October 1, 2009 - 1:00 pm - 5:00 pm
Carl Zeiss IMT - Maple Grove

Do you know the vital steps to review designs and processes for potential risks and failures?

Every new design or design/process change should be preceded by an FMEA. This will convert qualitative concerns into specific actions, highlight what possible negative effects could occur, and make sure that all the possible ramifications are understood.
In-house sessions available-call 763-383-9445




5S Improvements- Workplace Cleanliness Organization
Workshop on October 6, 2009 - 8:00 a.m. - 12 noon
The Reserve - Plymouth

Are you looking for more productivity and quality Improvements?

Practicing 5S can impact your customer and employee image, and regain lost productivity. 5S is a necessary building block to create the discipline and pride to become lean. It builds involvement and engagement across the workforce and allows employees to show pride in their area.

In-house sessions available-call 763-383-9445




Visual Management
Workshop on October 6, 2009 - 1:00 - 5:00 pm
The Reserve - Plymouth

Do you know ways to manage your firm without spoken words?

Visual Management can give performance feedback, provide incentive to hit goals, illustrate what is expected and recognize a job well done. Practice the fundamentals in a hands-on simulation, and see a broad array of examples.

In-house sessions available-call 763-383-9445




5S Improvements & Visual Management
on October 6, 2009 - 8:00 a.m. - 5:00 pm
The Reserve - Plymouth

Each HALF-DAY workshop can be taken independently or sign up for both and save.

5S Improvements--Workplace Cleanliness & Organization: Learn how to improve productivity and quality by employing 5S, a necessary building block for becoming lean.


Visual Management: In this hands-on workshop, learn how Visual Management can give real-time performance feedback, provide incentive to meet and exceed goals, illustrate what is expected of everyone each day and recognize a job well done.

In-house sessions available-call 763-383-9445



This Series includes:

Visual Management
When: October 6, 2009 from 1:00 to 5:00 pm
Where: The Reserve - Plymouth.

5S Improvements- Workplace Cleanliness Organization
When: October 6, 2009 from 8:00 a.m. to 12 noon
Where: The Reserve - Plymouth.



Leading Down New Paths
Supervisory Training on October 8, 2009 - 1:00 pm - 5:00 pm
Precision Gasket - Development Center (Building 3)

Designed specifically for manufacturers . . .
Leadership training for front-line managers, supervisors and team leaders!


Offered as part of the Learning to Lead Supervisory Training Series. Each series of six sessions may be taken sequentially or independently, depending upon experience and needs.

Additional Series: Essentials of Leading for Results
August 6 - September 10, 2009

Please note: To register for the entire Learning to Lead series go to the Training Series flyer.

In-house sessions available-call 763-383-9445




Leading and Training Improvement Teams
Workshop on October 15, 2009 - 8:30 am - 4:30 pm
To be announced

The cornerstone of implementing a Lean Enterprise is getting a critical mass of people on board working towards improvement.

Our experienced instructor, Lynn Moline, will lead attendees through interactive discussions and exercises that demonstrate effective improvement team leadership and training. Perfect workshop for team leaders and members.

In-house sessions available-call 763-383-9445




Office Process Mapping
Workshop on October 22, 2009 - 8:30 am - 4:30 pm
To be announced

This workshop is part of the Lean Office Mini Series. See the Lean Office Mini Series flyer for information on all of our Lean Office workshops.


Cut lead times . . . React faster . . . Eliminate more waste than ever!

Office Process Mapping is one of the most important tools for the lean office.
Applying lean concepts and tools to the office environment presents unique challenges. The ability to see and recognize our processes is paramount to our ability to drive process improvement. This hands-on workshop provides you with the knowledge and experience necessary to start implementing mapping in the office.

In-house sessions available-call 763-383-9445




Working with Different Personalities
Workshop on October 27, 2009 - 1:00 - 5:00 pm
Maple Grove Community Center

How do communication style differences affect your performance and your team’s?

Who Should Attend?
HR personnel, manufacturing managers, and those involved with teams.
What will be covered?
Dimensions of human behavior, communication styles (strengths and potential blind spots), modifying your behavior, verbal and non-verbal behavior styles, and understanding style differences.

In-house sessions available-call 763-383-9445




Lean Flow with TOC
Workshop on October 29, 2009 - 1:00 pm - 5:00 pm
Wooddale Church

Theory of Constraints, TOC, is an important tool for Lean Manufacturing.

Send teams to this practical, interactive workshop. Attendees participate in a simulation that demonstrates a more productive approach to flow.

In-house sessions available-call 763-383-9445




Mistake Proofing
Workshop on October 29, 2009 - 8:00 a.m. - 12 noon
Wooddale Church

Join your peers to learn Poke-Yoke techniques to eliminate defects.

People don’t want to make mistakes, but all workers make them. Learn how simple Poke-Yoke fool-proofing may remove the possibilities for error. Production devices or design for assembly criteria can eliminate mistakes before they happen. Achieve the reliable, continuous flow of Lean manufacturing.

In-house sessions available-call 763-383-9445




Setup Reduction
Workshop on November 10, 2009 - 8:30 am - 4:30 pm
The Reserve - Plymouth

Excellent workshop for machine operators!

Send teams to learn how to reduce setup times and eliminate waste on virtually any operation or machine.

Participants will learn the tools necessary to conduct a setup reduction event. These tools will then be applied to a simulated process where they will identify wastes, make improvements and track their progress.

In-house sessions available-call 763-383-9445




Advanced Visual Management
Workshop on November 17, 2009 - 1:00 - 5:00 pm
Maple Grove Community Center

You’re using shadow boards, kanbans, and floor markings…now what?

This advanced class builds from a Visual Management foundation to further enhance your visual factory. Expand your use of Visual Management techniques into the management of the entire work flow.

Participants are encouraged to bring examples of current practices for discussion.

In-house sessions available-call 763-383-9445




Kaizen Leadership
Workshop on November 17, 2009 - 8:00 am - 12 noon
Maple Grove Community Center

We know all about Kaizen events, but how do you lead one?

This half-day workshop will provide the education and experience that is necessary for you to lead Kaizen events.

In-house sessions available-call 763-383-9445




Robotic Applications & Implementation
Workshop on January 12, 2010 - 8:00 a.m. - 12 noon
The Hartfiel Company and Durabotics Inc.

Times have changed; it is easier now.

This course is aimed at companies who are interested in improving their productivity and reaping the financial benefits of Flexible Robotic Automation...OR...to determine if robotics is NOT the right fit for you.