Lean Process Improvement

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This two-day course will help 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 day will give participants tools to perform continuous improvement in their organization, including 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu, and various Lean data mapping methods.
No defined pre-requisites. While participants are likely to be in a supervisory or managerial role in their organisation, this is also an effective workshop to influence team members and help them understand the Lean process and how they can be a part of it.
After this course, participants will be able to:
• 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 data 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
Understanding Lean :
To start, participants will learn what Lean is and what its origins are. Participants will also learn about the Toyoda Precepts, how Lean differs from Six Sigma, and some common Lean terms.
The Toyota Production System :
The Toyota Production System House:
The Five Critical Improvement Concepts:
Continuous improvement
Understanding Value with the Kano Model:
Explore value with the Kano model:
Value added
Types of Waste:
The three main wastes:
Creating a Lean Enterprise:
Ways to create an environmentally friendly organization with Lean
John Bicheno’s 20 keys to a Lean organization
The Plan, Do, Study, Act (PDSA) Cycle:
PDSA cycle - used to plan and implement organizational changes
Using the R-DMAIC-S Model:
Lean Thinking Tools:
Genchi Genbutsu
Kaizen Events:
The five levels of Kaizen events (with a focus on Level 3 - the Kaizen blitz)
Data Gathering and Mapping:
Lean data tools
Flow charts
Ishikawa (cause and effect or fishbone) diagrams
SIPOC charts
Value stream maps
Tips for effective data analysis.
A Plan to Take Home:
Roadblocks and pitfalls to Lean implementation
Bringing Lean to your organisation
Ideas for Lean projects
A framework for a successful Lean approach
Workshop Wrap-Up:
Q & A
Action plan