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// WORKSHOP · LEAN × AI

AI in the daily work
of your teams

A workshop for manufacturing companies. We teach teams to analyze data from ERP, MES and spreadsheets, and to build their own tools and simple applications. On your data, for your processes.

Assembly hall with operators at their stations, a line utilization monitor and an engineer with a tablet
THE DATA YOU ALREADY HAVE · WAITING TO BE USED
1
DIAGNOSIS DAY
1–2
WORKSHOP DAYS
2×2
HOURS OF FOLLOW-UP
8–12
PARTICIPANTS
// STARTING POINT

Let’s start with the math

How many hours did your people spend stitching Excel files together this month? An export from one system, an export from another, manual column matching, checking the totals.
How many presentations were built overnight, the day before the meeting? The same charts, redrawn from scratch every month.
Specialist at a monitor with a monthly results spreadsheet and trend charts
THE SAME SPREADSHEET · EVERY MONTH · FROM SCRATCH

This is not a technology problem. The tools are already here — in most companies, nobody has taught people how to use them. It’s a competence gap, not a software gap.

// DIAGNOSIS

Why data analysis takes so long

Before we propose any tools, we break the problem down into causes. It’s the first thing we do at your site — and the first thing we teach at the workshop.

Ishikawa diagram: causes of long data analysis time Cause-and-effect analysis of long production data analysis time across six categories: systems, data, method, people, measurement and organization. // EFFECT LONG DATA ANALYSIS TIME 1 PERSON · 2 DAYS · MONTHLY SYSTEMS MES and ERP not connected Exports in different formats Access only through IT DATA Different KPI definitions Missing and duplicate records Files scattered across drives METHOD Report rebuilt from scratch Spreadsheets merged by hand Calculation logic never written down PEOPLE Knowledge in one person’s head No training on the tools Analysis done after hours METRICS Different reporting periods OEE calculated two ways Results never validated ORGANIZATION No data owner Priorities changed mid-stream Decisions made on week-old data

// SAMPLE ANALYSIS · YOURS WILL BE DIFFERENT

// THREE CONTROL QUESTIONS

Check this in your own plant

Are you really managing actions and projects — or just a task list in a spreadsheet? Who owns it, by when, and what happened to that task from last quarter.
Is your production data transparent — or does it have to be rebuilt from scratch every month? If the report is recreated from zero every time, it’s not a report. It’s a project.
Are Excel and PowerPoint still eating up entire working days? Count one person’s hours in a month and multiply by the number of people.
// HOW WE WORK

We don’t start with tools.
We start with you

011 DAY

Diagnosis before the workshop

  • Conversations with management and with the people who actually build the reports
  • A review of what is produced manually today and how much time it costs
  • Pinpointing where it hurts: operations, administration or logistics
  • Selection of 3–5 real tasks as workshop material
021–2 DAYS

Workshop on your data

  • One or two days of hands-on work at laptops, depending on the scope agreed in the diagnosis
  • Each participant works on a task from their own department
  • You leave with working tools, not with notes
032 × 2 H

Two follow-up sessions

  • A session after 2 weeks of use — the first independent tasks and whatever got stuck
  • A session after 4 weeks — refining the tools and finding new applications
  • Two hours each, remote, with the whole group at once

The diagnosis is included in the workshop price. We don’t run training without it — a workshop built on made-up examples is a waste of your people’s time.

// PHASE 1 · DIAGNOSIS

What we establish before we enter the room

An “AI training” without this stage ends in enthusiasm that fades within a week. The diagnosis decides whether the workshop changes anything.

Diagnostic meeting next to the shop floor: a consultant taking notes, the client’s team mapping processes on a board with sticky notes
LAPTOPS CLOSED · CONVERSATION OPEN
  • Where the time goes. Which reports, summaries and presentations are built by hand, how often, and how many people are involved.
  • What data you really have. What can be pulled from ERP and MES, in what form and how often. What lives only in spreadsheets.
  • Who will actually use it. The participants’ level, their daily tasks, and the constraints on the IT and data security side.
  • What the outcome should be. Specific tools to be built during the workshop, agreed with you before we start.
// PHASE 2 · WORKSHOP

Four skills

01

Multi-source data analysis

A dozen files from ERP, MES and spreadsheets at once — one coherent analysis. Plus a way to check whether the result is true.

02

Projects and repeatability

A project where the context and calculation logic stay written down. The knowledge stays in the company, not in one person’s head.

03

Your own tools

Dashboards, calculators, checklists, report generators. Excel and PowerPoint get done many times faster.

04

Simple applications

Tools that work on the shop floor and in the office from tomorrow. No developer and no deployment project.

Workshop next to the production hall: six participants working on their own laptops with dashboards, the trainer leaning over one participant’s shoulder
LAPTOPS OPEN · YOUR OWN TASKS

We work with Claude and ChatGPT — tools you already have or can have within a week. No system rollout, no integrations, no IT budget to get started.

// PROGRAM · SCOPE

Four modules. All on your data

The scope is fixed, the examples are yours. After the diagnosis we know what each module should practice on, so every participant leaves with a working tool rather than an exercise on a made-up dataset.

01

Work environment

Profile, projects, files, shared drives, data security.

02

Data and tools

Excel with formulas, dashboards, calculators, presentations.

03

From paper to digital

Photos of boards, notes and printouts turned into data.

04

Everyday work

Meeting minutes, project sheets, A3s, brainstorming.

Modules 1 and 2 are for everyone. Modules 3 and 4 are weighted according to where your company loses the most time.

// MODULE 01

A working environment, not party tricks

Day one is about setting up the workbench. Without it, every next task starts from zero and ends with a random result.

  • Profile and project configuration. Standing instructions, company context, a glossary of industry terms and the expected answer style — set once, working in every task.
  • Working with files. A dozen spreadsheets at once, formats, limits, and concrete ways to handle a dataset that doesn’t fit.
  • Shared drives. Google Drive and SharePoint as the team’s data source, not one person’s private desktop folder.
  • Judging the output. When a number can be trusted and when it has to be checked — and how to check it fast, without recalculating everything a second time.
  • Security. What may be uploaded, what may not, and how to work with personal and sensitive data. Agreed with your IT before the workshop.
// MODULE 02

Data and tools

The most hands-on part of the workshop. This is where every participant builds something to take back to their own department.

  • Excel spreadsheets. With working formulas, pivot tables and validation — not just numbers pasted into a grid.
  • Combining sources. Exports from ERP, MES and spreadsheets pulled into one coherent analysis, with a check that the totals add up.
  • Dashboards. With file upload and result download, usable by the whole team without asking the author for help.
  • Calculators and tools. For calculations you repeat every week or every shift — built once, they keep working on their own.
  • Presentations. From raw data to finished slides, without copy-pasting charts and formatting late into the night.
Workstation: an Excel spreadsheet and a PowerPoint presentation on the monitors, above them a TV with a digital SQDCP board in green, orange and red
FROM SPREADSHEET TO SHOP-FLOOR BOARD
// MODULE 03

A photo instead of retyping

Most data in a factory is still born on paper. This module teaches how to move it into a spreadsheet without retyping and without buying anything.

  • A photo of a board or a sheet of paper. Notes from a workshop or a meeting turned into a spreadsheet with proper columns, ready for sorting and calculating.
  • Shop-floor photos as a data source. Labels, meter readings, control cards, forms filled in by hand during the shift.
  • Printouts and scans. Paper documents turned into numbers that can be compiled and compared across periods.
  • A sketch on paper. A hand drawing turned into a presentation, a spreadsheet or a working tool — within a single meeting.
  • Digitizing documentation. A binder becomes a database you can search. No retyping and no hiring someone to do the retyping.
A quality control card filled in by hand, photographed with a phone, next to a laptop showing the same table as a spreadsheet with a chart
ONE PHOTO · A READY SPREADSHEET
// MODULE 04

The team’s everyday work

The things that eat time every single week and that nobody counts, because “it only takes a minute”. This is where you reclaim the most hours with the least effort.

Meeting room after the meeting: an A3 sheet on the board, yellow sticky notes, a Gantt chart on the screen, meeting minutes on a laptop
WHAT REMAINS AFTER THE MEETING
  • Meeting minutes. Decisions, task owners and deadlines, sent out before people leave the room. A list of commitments, not a summary of the discussion.
  • Project sheets. Scope, milestones, risks and status in one place, updated without copy-pasting between files.
  • A3. Problem, root cause analysis, action plan and metrics on a single page — in the format you already know from Lean.
  • Brainstorming. Generating options and structuring what came up in the meeting, instead of a board of sticky notes nobody ever transcribes.
  • Action tracking. What happened to that task from last quarter, who was supposed to close it and why it’s stuck.
// EXAMPLE

Not just production. Every department

Four tools built by participants on their own departments’ data.

Production dashboard: assembly line OEEOEE 78 percent, takt 118 seconds, actual cycle time 134 seconds, 31-day performance trend. // PRODUCTIONASSEMBLY LINE · SHIFT A OEE 78% TAKT118 s CT REAL134 s PERFORMANCE · 31 DAYSVS. PREV. MONTH+12.4% Quality dashboard: customer complaints reportTwelve complaints, down 38 percent, Pareto of complaint causes. // QUALITYCOMPLAINTS · MONTH CLAIMS12 VS. PREVIOUS−38% RESP. TIME2.4 d CAUSES · PARETODIMENSIONCOATINGASSEMBLYDOCSTRANSP.// 2 CAUSES = 64% OF CLAIMS HR dashboard: training plan completionTraining plan 84 percent complete, 1,240 hours, 318 participants, breakdown by department. // HRTRAINING · PLAN COMPLETION ANNUAL PLAN84% HOURS1,240 PARTICIPANTS318 BY DEPARTMENTPRODUCTION94%MAINTENANCE88%QUALITY79%LOGISTICS66%ADMINISTRATION52% Logistics dashboard: warehouse utilizationSlot occupancy 86 percent, turnover 7.2 times, utilization of four warehouse zones. // LOGISTICSWAREHOUSE · UTILIZATION SLOT OCCUPANCY 86% TURNOVER7.2× FREE412 BY ZONEA · RECEIVING71%B · HIGH BAY93%C · PICKING82%D · SHIPPING64%// ZONE B NEAR LIMIT

// ILLUSTRATIVE EXAMPLES · ANONYMIZED DATA

// SPEED

Not just “faster”. Exactly this much

Four reports that take half a day or a full day today. Below, the time they take after the workshop — from typing the prompt to the finished file.

  • 70 s
    Line downtime report Pareto of causes, ranking, table of shift events.
  • 120 s
    Weekly attendance report Shift grid, staffing gaps, a summary for the manager.
  • 40 s
    Skills matrix update Levels for the whole team, gaps visible at a glance.
  • 140 s
    Overtime report — 250 people, one month A named list, department totals, limit overruns.
Four panels: the same person at a laptop generating, one after another, a downtime report, an attendance report, a skills matrix and an overtime report, with the completion time in the corner of each panel
FROM PROMPT TO FINISHED REPORT

These are not sales-deck numbers — this is how long generating a report takes once the data is prepared and the project is configured. We teach the configuration in module 01 and the data preparation in module 02.

// OUTCOME

What remains after we leave

The biggest risk of training is not that it fails. It’s enthusiasm that fades in two weeks. That’s why we measure the outcome by what stays in the company after we walk out.

// LEVEL 1

For the participant

  • At least one working tool, built on their own department’s data and ready to use on Monday
  • A configured profile and project — the next task starts with work, not with setup
  • The ability to judge when a result can be trusted. That’s what separates using AI from playing with AI
// LEVEL 2

In the team

  • A library of proven ways of working, shared by the whole department, not private to the author
  • The calculation logic written down — the report stops depending on one person and their vacation
  • A new person gets up to speed in a day instead of a quarter
// LEVEL 3

In the company

  • A standard for working with data, agreed with your IT and security teams — not quietly worked around
  • A list of the next tasks to automate, ranked by the time they would recover
  • Two follow-up sessions of two hours each — after 2 and 4 weeks of use, when the first problems appear
// WHO IT’S FOR

We shape the program around roles

The same workshop, different applications. Everyone works on tasks from their own area.

Production manager on the shop floor with a tablet, a dashboard with a chart on the screen

Production managers

Shift reports, downtime analysis, OEE, preparing data for management meetings.

Process engineer at a workbench with calipers, next to a laptop with a scatter plot

Engineers and technologists

Scrap analysis, measurement data, technical documentation, process variant comparisons.

Continuous improvement manager at a board with a process map and yellow sticky notes

CI and quality managers

Pareto, root cause analysis, corrective action tracking, 8D and audit reports.

HR specialist at a desk, a spreadsheet with a highlighted column on the screen, greenery outside the window

HR, logistics, finance

Staffing and absence, delivery planning, inventory levels, cost summaries.

// TRAINER · SHOP-FLOOR PRACTITIONER

Adam Fieduk

Adam Fieduk, founder of makeXcellence

25+ years of operations management in international manufacturing plants. Greenfields, optimization, Lean transformations — across nine countries and eight industry sectors.

For the past two years he has been actively deploying AI in manufacturing companies across Europe — as an expert collaborating with a technology startup that builds digital products for industry. Creator of the LEAI concept: Lean, TOC and OPEX combined with AI.

A consultant and transformation leader. Not a lecturer — someone who has laid out lines himself, fought bottlenecks and built those reports late at night.

LEAN · TOC · OPEXOPS MANAGEMENTAI · MES · OEELEAI
25+
YEARS IN MANUFACTURING
9
COUNTRIES
200+
PROJECTS
// NEXT STEP

We start with your problem,
not with our slide deck

The first conversation costs nothing. In thirty minutes we’ll establish whether the workshop makes sense for you — and what exactly it should change.

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