LEAN PROCESS IMPROVEMENT COURSE

Description


Lean process improvement course will teach a system of steps that help organizations reduce waste by focusing on customer value. By identifying how customer value flows across every aspect of the organization, management & teams can then fine-tune and implement processes that create zero waste.

 

This training course will enable teams with the right tools to implement lean principles of process improvement into the very core of their culture, reducing waste and improving product and service value to the customer. Tools covered include 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu.

 

This two-day Lean Process Improvement course will give your organization the foundation tools it requires to implement Lean.

Day one will explore the foundation Toyota precepts of Lean and the five improvement concepts – value, waste, variation, complexity, and continuous improvement.

 

The second day will focus on the actual tools for implementing these continual improvement concepts in their organization. Useful tools will include; Lean data mapping methods, 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu.

 

Perhaps the biggest differentiation between the generic term “process improvement”, and the Lean process improvement methodology, is that Lean process improvement is a mindset and a practice — not an event.Many organizations view process improvement as a temporary event or activity used to solve giant systematic gaps. Lean organizations view continuous improvement as a daily mindset and practice — the means by which organizations are able to deliver on their promises to their customers.

 

This Lean process improvement training course will enable an entire organization to holistically apply lean thinking across every aspect of their value stream. From the worker to the CEO, the constant reevaluation of the value stream across each product and service family will challenge old thinking and create a new culture of lean thinking. Once the value of a product or service is identified, then unnecessary waste can be removed with continual process improvement.

 

Lean is not just limited to manufacturing and production, but also can equally be applied to service oriented industries like healthcare, government, education and agribusiness.

 

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Course Objective


  • Gain an understanding of Lean
  • Describe "The Toyota Production System" and TPS house.
  • Master the five lean principles
  • Learn how to categorize products or systems into the three groups
  • Learn how to create and contribute to a lean enterprise
  • Identify and reduce various types of waste
  • Learn to create a plan for an organization that's more environmentally Lean
  • Learn how to implement & evaluate Lean changes with PDSA cycle R-DMAIC-S models
  • Learn how to effectively use lean thinking frameworks like 5W-2H, Genchi Genbutsu, Gemba, and 5-S
  • Prepare for and complete a basic 5-S
  • Learn the five levels of Kaizen events, particularly a Kaizen blitz
  • Effective tips for data gathering, mapping and analysis using flow charts, Ishikawa and SIPOC diagrams, and value stream maps
  • Create a successful plan for a lean project

Modules


Lean Process Improvement Training Course - Lesson 1 Course Overview
  • Course Objectives
Lean Process Improvement Training Course - Lesson 2 Understanding Lean
  • Participants will learn what Lean is and what its origins are. This session will explore the Toyota Precepts, how Lean differs from Six Sigma, and some common Lean terms.
Lean Process Improvement Training Course - Lesson 3 The Toyota Production System
  • Participants will learn about the Toyota Production System House. Discover an alternate representation of the Toyota Production System.
Lean Process Improvement Training Course - Lesson 4 The Toyota Production System House
  • The Toyota Production System House
Lean Process Improvement Training Course - Lesson 5 The Five Critical Improvement Concepts
  • Discuss five key ideas supporting Lean process improvement: value, waste, variation, complexity, and continuous improvement.
Lean Process Improvement Training Course - Lesson 6 Understanding Value with the Kano Model
  • This session will explore value with the Kano model, which divides product or system characteristics into three groups: basic, performance, and value added.
Lean Process Improvement Training Course - Lesson 7 Types of Waste
  • In this session participants learn about the three main wastes (muda, muri, and mura) as well as some new types.
Lean Process Improvement Training Course - Lesson 8 Creating a Lean Enterprise
  • Explore some ways to create an environmentally friendly organisation with Lean. Learn about the 20 keys to a Lean organisation.
Lean Process Improvement Training Course - Lesson 9 The Plan, Do, Study, Act (PDSA) Cycle
  • The first session of Day Two will cover the PDSA cycle, which should be used to plan and implement organizational changes.
Lean Process Improvement Training Course - Lesson 10 Using the R-DMAIC-S Model
  • This session will cover the Recognize - Define - Measure - Analyse - Improve - Control – Sustain model, an advanced version of PDSA primarily used in Six Sigma.
Lean Process Improvement Training Course - Lesson 11 Lean Thinking Tools
  • Learn about some Lean thinking tools, including 5W-2H, Genchi Genbutsu, Gemba, and 5-S.
Lean Process Improvement Training Course - Lesson 12 Kaizen Events
  • This session will cover the five levels of Kaizen events, with a focus on Level 3 (the Kaizen blitz).
Lean Process Improvement Training Course - Lesson 13 Data Gathering and Mapping
  • Most of the second afternoon will be spent learning about and practicing various Lean data tools, including flow charts, Ishikawa (cause and effect or fishbone) diagrams, SIPOC charts, and value stream maps. We will also share some tips for effective data analysis.
Lean Process Improvement Training Course - Lesson 14 A Plan to Take Home
  • The final session will challenge participants to think about roadblocks and pitfalls to Lean implementation and how to bring those lessons to their organisation. Participants will also be given some ideas for Lean projects and a framework for a successful Lean approach.
Lean Process Improvement Training Course - Lesson 15 Workshop Wrap-Up
  • Participants will have an opportunity to ask questions and fill out an action plan

- Flexible length - sessions as short as 1-hour
- Cost effective - great group pricing
- Greatest impact in the shortest time
- Excellent Team Building Opportunity
- Certificate of Completion

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