Lean Process Improvement

Course details

Lean principles have come a long way over the past three hundred years. From Benjamin Franklin's early ideas, to Henry Ford's work in the 1920's and the Toyoda precepts in the 1930's, to Jeffery Liker's publication of The Toyota Way in 2004, Lean processes have evolved from a simple concept to a set of widely used best practices.

This two-day course will help you give participants the foundation to begin implementing Lean process improvement tools in their workplace. The first day will explore the foundations of Lean through the Toyota precepts and the five critical improvement concepts (value, waste, variation, complexity, and continuous improvement). The second doy will give participants tools to perform continuous improvement in their organization, inducing 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu, and various Lean data mapping methods.

Expected Accomplishments

• Define Lean and its key terms
• Describe the Toyota Production System and the TPS house
• Describe the five critical improvement concepts
• Use the Kano model to understand, describe, analyze, and improve value
• Identify and reduce various types of waste
• Create a plan for a more environmentally Lean organization
• Use the PDSA and R-DMAIC-S models to plan, execute, and evaluate Lean changes
• Use Lean thinking frameworks, including 5W-2H, Genchi Genbutsu and Gemba
• Prepare for and complete a basic 5-S
• Describe the key elements of Kaizen events, particularly a Kaizen blitz
• Gather, analyze, and interpret dato using flow charts, Ishikawa (fishbone) diagrams, SIPOC diagrams, and value stream maps
• Go back to their organization with a plan to begin incorporating Lean into their corporate culture

Course Outline

• Introduction and Course Overview
• Understanding Lean
• The Toyota Production System
• The Toyota Production System House
• The Five Critical Improvement Concepts
• Understanding Value with the Kano Model
• Types of Wosfe
• Creating a Lean Enterprise
• The Plan, Do, Study, Act (PDSA) Cycle
• Using the R-DMAIC-S Model
• Lean Thinking Tools
• Kaizen Events
• Data Gathering and Mapping
• A Plan to Take Home

Who Can Benefit

• Managers, supervisors and team leaders

Related Training

• Change management and how to lead Change
• High Performance Management Skills Toolbox
• Supply Change Management and Business Competitive Advantage
• Successful Product Management

mode

• Consultant led class with small interactive sessions

Prerequisites

• Good communication skills