Lean Process Improvement
Details
Lean principles have come a long way over the past 300 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 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.
- 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
Outline
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.
Next, participants will learn about the Toyota Production System as presented by Jeffery Liker.
In this session, participants will learn about another representation of the Toyota Production System.
Then, you will discuss five key ideas supporting Lean process improvement: value, waste, variation, complexity, and continuous improvement.
This session will explore value with the Kano model, which divides product or system characteristics into three groups: basic, performance, and value added.
In this session, participants will learn about the three main wastes (muda, muri, and mura) as well as some new types.
Next, participants will explore some ways to create an environmentally friendly organization with Lean. They will also learn about John Bicheno’s 20 keys to a Lean organization.
The first session of Day Two will cover the PDSA cycle, which should be used to plan and implement organizational changes.
This session will cover the Recognize – Define – Measure – Analyze – Improve – Control – Sustain model, an advanced version of PDSA primarily used in Six Sigma.
Next, participants will learn about some Lean thinking tools, including 5W-2H, Genchi Genbutsu, Gemba, and 5-S.
This session will cover the five levels of Kaizen events, with a focus on Level 3 (the Kaizen blitz).
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.
The final session will challenge participants to think about roadblocks and pitfalls to Lean implementation and how to bring those lessons to their organization. Participants will also be given some ideas for Lean projects and a framework for a successful Lean approach.
Our focus is on the development of real skills and practical solutions that are easy to apply immediately following the training session. Our programs are high impact and interactive sessions that are devoted to getting participants to reach peak performance. Real skills are sustainable, hype is short-lived.
Our training programs have been meticulously developed with a strategic team that included professional content writers, research specialists, in-field executive professionals and certified human resource professionals. Our premium quality content ensures high impact results. We invite you to browse our complete inventory of training programs on our website.
Why is Training Critical?
People are essential to the growth and success of any business. The greatest asset that any company has is the abilities of its team. Leading organizations understand that effective and consistent training will ensure continuous success and growth.
Effective training is focused on enhancing the inherent skills of an individual. It provides solutions that will increase productivity, performance and even personal growth, such as: behaviours, communication skills, better business practices and increased motivation. ...