Dagher Institute for Professionals

SmartLean Agility Nexus by Dr. Charles Dagher



Next-Gen Talent Boosters



Our Manufacturing Mastery Series equip professionals with the skills and strategies to optimize resources, foster innovation, and maximize productivity and profitability in a competitive market.





Managing Resistance to Change in the Workplace



Companies must adapt to business trends, but real change happens only when their people do.





Change signifies improvement but requires effort and time, depending on an organization's readiness. Approximately 80% of improvements stem from cultural shifts, as effective change relies on both human and technical advancements. While culture and behavior drive the majority of change, technical solutions enable its execution.




Duration: 8 hours


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General Manager Excellence:



Modern Management Tools for Lean, Agility, and Sustained Performance





The program will provide a clear view on how operations should be managed today with an illustration of tools and techniques that both implement and support the lean manufacturing. These techniques are more generally called Modern Management tools in the era of just in time. Overall, the attendees will realize the way of thinking and supporting toward overall sustained performance and profitability.


Duration: 16 hours


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Lean Management Enterprise:



Overcoming Uncertainty and Driving Manufacturing Excellence with Lean Principles





Organizations hesitate to embrace Lean for optimizing manufacturing costs, influenced by past misapplications that create uncertainty. However, Lean isn’t about starting from scratch—it’s about leveraging strengths. Without proper guidance on how Lean elevates manufacturing, the industry will remain reluctant to adopt it. This program helps senior executives understand Lean principles and strategies to drive manufacturing excellence.


Duration: 8 hours


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THE LEAN OFFICE:
Enhancing Workflow and Performance





This program equips professionals with Lean Office principles to streamline workflows, eliminate inefficiencies, and enhance productivity in office environments. Participants will learn to apply Lean tools to improve decision-making, reduce costs, and accelerate processes in areas such as merchandising, HR, unit costing, and document management. By fostering a culture of continuous improvement and collaboration, this program enables organizations to achieve operational excellence, adaptability, and superior service delivery in today’s fast-paced business landscape.



Duration: 24 hours


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THE VISUAL FACTORY:
5S and Visual Management in Action





This program focuses on addressing common challenges in apparel manufacturing by implementing 5S and visual controls to improve workflow efficiency, product quality, safety, and communication. Participants will gain practical skills to streamline work processes, create organized workspaces, and establish visual management systems that foster continuous improvement. By aligning 5S with visual controls, the program enables participants to reduce waste, enhance productivity, and sustain long-term improvements, empowering them to lead lean initiatives in their factory environments.



Duration: 16 hours


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THE VISUAL OFFICE:
Implementing 5S and Visual Management





This program addresses inefficiencies in office environments by implementing 5S principles and visual displays and controls. Participants will learn to organize workspaces, streamline workflows, and improve information accessibility, reducing waste and boosting productivity. By aligning 5S with visual standards, the program creates a more efficient, organized, and responsive office, leading to better decision-making, improved engagement, and optimized resource use. Participants will be equipped to transform office operations and enhance organizational performance.



Duration: 8 hours


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MASTERING VALUE STREAM MAPPING:
Unlocking Efficiency and Excellence





Many improvement teams wrongly apply Value Stream Mapping (VSM) in labor-intensive industries by focusing only on material flow and retention times, which limits improvements to lead time. This program teaches the correct approach to VSM, helping participants improve material flow as well as processes and systems across all manufacturing stages. VSM outcomes also lead to better resource utilization analysis. Participants will learn techniques to map flow, use tools to analyze processes, and design more efficient workflows, optimize resources, balance workloads, reduce lead times, lower Work In Progress (WIP), and enhance overall agility.



Duration: 8 hours


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ADVANCED ENGINEERING CAPABILITIES:
Optimizing Manufacturing Resources




The manufacturing landscape lacks forward-thinking engineering approaches to optimize resources, limiting productivity improvement. This program equips apparel professionals with advanced engineering skills to optimize and modernize operations. Traditional work-study methods fall short in today’s fast-evolving industry, where agility drives improvements. Participants will assess resources, identify inefficiencies, and implement solutions. The program covers assessment techniques, problem-solving, and process optimization, empowering participants to adopt modern engineering approaches for long-term competitiveness and operational excellence.


Duration: 16 hours


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TOTAL PRODUCTIVIE MAINTENANCE:
Maximizing Resource Efficiency





Machinery failure is a key challenge in manufacturing, impacting resource utilization, disrupting balance, increasing WIP, and significantly reducing overall productivity. The Total Productive Maintenance (TPM) program aims to optimize equipment performance, reduce downtime, and enhance operational efficiency in factories. By involving operators in proactive and regular preventive maintenance, TPM fosters strategies that improve machinery effectiveness, product quality, and overall productivity. This program equips participants with the skills, tools, and actionable plans to implement TPM effectively, reduce operational costs, and ensure optimal resource utilization.



Duration: 4 hours


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Optimizing Cutting Room Workflows for Maximum Resource Utilization





The cutting room’s complex multi-handling processes make resource synchronization and optimization challenging, especially without an engineering-driven approach. Inefficiencies result in wasted resources, production delays, high inventory levels, and reduced profitability. Often overlooked by engineers, this area presents significant opportunities for improvement. This training program equips participants with the skills to optimize equipment, labor, and inventory by applying engineering and lean techniques. They will learn to assess processes, identify inefficiencies, and implement strategies to create a more agile, cost-effective cutting room with faster turnaround times and improved performance.



Duration: 16 hours


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Building Agile and Optimal Sewing Teams for Peak Performance




Many leaders hesitate to adopt new concepts in the sewing area due to perceived complexity in skill development and the need for infrastructure changes, often missing significant opportunities for improvement. Additionally, traditional work-study methods lack the capacity to demonstrate financial gains through optimization and system agility, crucial for building confidence among decision-makers in pursuing changes. This training program introduces cutting-edge engineering approaches, equipping participants with techniques to optimize resources, develop an agile workforce, and boost overall productivity. These achievements will help build the confidence needed among decision-makers to embrace transformation.


Duration: 16 hours


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Transforming Finishing and Packing
for Agility and Efficiency





The finishing and packing area has often been overlooked by engineering teams in terms of optimization and productivity enhancement. This program equips participants with advanced skills and techniques to build agile, flexible teams that can quickly adapt to challenges, reduce lead times, and achieve peak performance. Participants will learn to assess workflows, streamline processes, and foster collaboration to enhance flexibility, speed, and resource utilization. By applying agility principles to real-world scenarios, teams will effectively respond to production demands, minimize inventory, and eliminate bottlenecks, ultimately creating a resilient workforce ready for future challenges.



Duration: 8 hours


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ACCELERATED PRODUCT SAMPLE MAKING:
A Strategic Edge in Market Competitiveness





In today’s manufacturing industry, sample rooms often rely on traditional structures with no organized systems or workflow, leading to unpredictable and inefficient processes. Streamlining the sample-making process is crucial to staying competitive in this fast-paced environment. This program applies Just-In-Time (JIT) principles to optimize workflows and improve responsiveness. By refining processes and using lean tools, factories can reduce lead times and costs while maintaining quality. Participants will gain the expertise to accelerate processes, enhance agility, and exceed customer expectations.


Duration: 16 hours


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UNIFYING MANAGEMENT SYSTEMS:
Driving Timely, Disruption-Free Production




In manufacturing companies, production delays can arise from various factors that significantly affect resource utilization and disrupt product flow, ultimately leading to decreased productivity. These delays waste time, slow processes, and create bottlenecks. Issues such as inadequate internal supplies, poor information flow, equipment failures, or a lack of commitment to continuous improvement can even halt production completely, worsening the situation. Participants will acquire the knowledge and skills needed to streamline management systems and cultivate a culture of continuous improvement.


Duration: 16 hours


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AGILE WORKFORCE DEVELOPMENT:
Empowering Trainers for Evolving Systems





Most skills development programs focus on adapting workers to traditional methods, emphasizing individual performance rather than fostering agility and adaptability to evolving systems. Today’s industry demands a flexible, agile workforce supported by modern lean production systems that promote teamwork, collaboration, and quick order changeovers. Additionally, engaging supervisors in value-driven tasks enhances overall performance. This program equips participants with the expertise and methodologies to develop an agile, adaptable workforce, leading to higher efficiency and increased productivity.



Duration: 16 hours


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