TPM Pillar · Critical competencies per process

The problem we solve

What it's for.

In many operations, training is an aimless list of courses: no one knows for certain who has mastered each critical task, or which skill gap is costing a goal. Our system solves it at the root, in four moves we run today in real U.S. manufacturing. The fine detail of the method is part of the service, not the brochure.

A plant team training session led by our founder in Colombia: skills systems are built on the floor, with the people.

Root cause per activity

We document every process activity that directly affects a KPI or a strategic goal: costs, losses, rework, deliveries.

The 80/20 of knowledge

A few unmastered skills — from managers to operators — concentrate most of the losses. Paretos reveal them.

Gap closing

The skills and competency matrix evaluates real performance and aims training where it hurts most, with certification.

Knowledge multiplication

Cross training, check routes that rotate every month, and trainers of trainers inside your own team.

Ideal for

This fits you if…

Plant operations

Want to know for certain who has mastered each critical task, without relying on the supervisor's memory.

Leaders chasing goals

A goal keeps slipping month after month and they need to see which skill gap sits behind it.

Teams training without direction

Run disconnected courses and want a system that trains where it truly hurts.

TPM pillars being set up

Building their Skills Development pillar and need method and structure.

TPM Pillar · Skills developmentSkills and competency matrixParetos per goalCross training · VersatilityTrainer of trainers · ILUOMonthly check routesLAOS cycle

What we set up

The complete system, hand in hand with TPM.

Activity analysis per process

With root-cause analysis we document every activity that can directly affect a KPI or a strategic goal.

Documented standards

What must be mastered gets documented: the base for training, evaluating, and certifying without relying on anyone's memory.

Skills and competency matrix

The map of who has mastered what, at what level: the objective base for evaluating each collaborator's performance and closing their gaps.

Paretos tied to goals

Paretos show the 80/20: which few knowledge gaps concentrate most of the losses and the shortfall.

Gap-closing plan

The path attacks first the competencies that move the goal, with owner, evaluation, and certification per competency.

Versatility and cross training

We train the team across more than one station to create experts, so no critical task depends on a single person.

Monthly check routes

Verification routes for critical competencies that change every month and keep the system alive with the LAOS cycle.

Trainer of trainers (ILUO)

Not everyone knows how to transmit knowledge: we develop your experts and leaders with ILUO so they train others and the system multiplies.

What you get

Concrete results.

Critical activities and skills analyzed per process

Skills and competency matrix to evaluate performance

Paretos connecting each gap to the goal it affects

Gap-closing plan with evaluation and certification

Versatility and cross training: experts across stations

Check routes for critical competencies that rotate monthly

Leaders developed as trainers of trainers (ILUO)

Honest limits

What this solution does not include.

Delivering every course in the plan: we set up the system and the roadmap; running each training is quoted separately or handled by your team

A guarantee the goal will be met: we close the skill gap, but the result also depends on process, equipment, and discipline

Official competency certification issued by external bodies

Templates or method manuals to replicate it on your own: the system is implemented with you, not handed over as a recipe

Specialized talent-management software: we use simple tools (Excel/Power BI or the system you already have)

Hiring, payroll, or organizational structure changes

How we work

A clear process, step by step.

Initial diagnosis

A free conversation about your operation, your data and the result you are after.

Scope and proposal

We define deliverables, timeline and price in writing before starting.

Phased execution

We work in short iterations, with visible progress you can review at each delivery.

Validation with data

We measure the result against the baseline: improvement is shown with numbers, not promised.

Handoff and transfer

You receive the documented result, and your team the knowledge to sustain it without us.

Investment

Scope first, price after.

DiagnosisWe map your operation and its baseline first

MethodProcess + technology, with a defined scope

Measurable resultDeliverables and KPIs your team can sustain

Custom quote

Final scope is defined after an initial call.

FAQ

Frequently asked questions

We start from the goals that are not being met and analyze them with Paretos: it's the 80/20 of knowledge — a few causes concentrate most of the losses, and behind almost every cause there is a skill someone has not yet mastered, at any level of the company. The training plan attacks those gaps first, and progress is read in the goal, not in course attendance.

The training programs deliver instruction (Green Belt and Black Belt paths). This service sets up the system behind them: activity analysis, the competency matrix, Paretos per goal, and certification, so each course closes a concrete gap instead of being part of a loose list.

It's the map that crosses each person with the key activities of their process and shows the level at which they've mastered each one. It's the objective base for evaluating real performance, planning versatility (cross training), and deciding who develops into an expert — and it reveals where you depend on a single person.

Not every expert knows how to transmit what they master: teaching is a separate skill, and it can be trained too. With ILUO we develop your best collaborators and leaders so they evaluate, certify, and train others — the knowledge multiplies inside your team without depending on outside consultants.

You stop depending on irreplaceable people: every critical task has at least two people who master it. New hires train through clear paths instead of "watching how it's done". Performance evaluation becomes objective, with the matrix on the table. And training stops being aimless spending: it aims exactly at the gaps that concentrate your losses.

It's the TPM Skills Development pillar, built with Lean tools and our LAOS cycle (Learn, Align, Optimize, Sustain). It works the same on a plant floor and in administrative processes, and applies at every level: managers, supervisors, and operators.

We deliver the system working in your operation: matrices, standards, Paretos, and routines, with your team trained to sustain it. The fine design of the method is the consultancy's know-how: it is implemented with you, not handed over as a template.

Price is determined after an initial call, based on the number of processes and areas to analyze and the depth of the system.

Shall we talk about your project?

Initial conversation with no commitment. Tell us what you need and we'll tell you how we can help — and if it's not our thing, we'll point you in the right direction.

Tell us about your operation Talk to us

Legal notice

ESPAÑOL

León & Asociados LLC es una empresa de consultoría profesional registrada en el estado de Minnesota. Ofrecemos dos líneas de solución: (1) preparación de formularios y documentación migratoria, y (2) consultoría en optimización de procesos, análisis de datos, metodología Lean Six Sigma y automatización.

León & Asociados LLC NO es una firma de abogados y ninguno de sus representantes es abogado, ingeniero profesional licenciado (PE), ni asesor legal o financiero.

Las soluciones de preparación migratoria se limitan a la organización y preparación de formularios conforme a las instrucciones oficiales de USCIS; no constituyen asesoría legal de ningún tipo. Las soluciones de consultoría técnica se basan en metodologías de mejora de procesos y análisis de datos; no constituyen práctica profesional de ingeniería regulada.

Para asuntos que requieran representación legal migratoria o soluciones de ingeniería profesional licenciada, León & Asociados LLC recomienda consultar con un abogado de inmigración licenciado o un ingeniero profesional (PE) con licencia activa.

ENGLISH

León & Asociados LLC is a professional consulting firm registered in the state of Minnesota. We offer two lines of service: (1) preparation of immigration forms and documentation, and (2) consulting in process optimization, data analysis, Lean Six Sigma methodology, and automation.

León & Asociados LLC is NOT a law firm, and none of its representatives is an attorney, licensed professional engineer (PE), or legal or financial advisor.

Immigration preparation solutions are limited to the organization and preparation of forms in accordance with the official USCIS instructions; they do not constitute legal advice of any kind. Technical consulting solutions are based on process-improvement methodologies and data analysis; they do not constitute the regulated professional practice of engineering.

For matters requiring legal immigration representation or licensed professional engineering solutions, León & Asociados LLC recommends consulting a licensed immigration attorney or a professional engineer (PE) with an active license.

León & Asociados LLC · Professional consulting · Not a law firm or licensed engineering firm · Minnesota, USA