Lean Process Improvement Course

Lean Process Improvement Course

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 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 of Toyota precepts of Lean and the five improvement concepts – value, waste, variation, complexity, and continuous improvement.

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

Perhaps the most significant 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 to solve giant systematic gaps. Lean organizations view continuous improvement as a daily mindset and practice — how organizations can 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, the unnecessary waste can be removed with continual process improvement.

Lean is limited to manufacturing and production and can also be applied to service-oriented industries like healthcare, government, education, and agribusiness.

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Course Objectives

  • 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

Course Objectives

Lesson 1 – Course Overview
  • Course Objectives
Lesson 2 – Understanding Lean
  • Participants will learn what Lean is and what its origins are. This session will explore Toyota Precepts, how Lean differs from Six Sigma, and some common Lean terms.
Lesson 3 – The Toyota Production System
  • Participants will learn about the Toyota Production System House. Discover an alternate representation of the Toyota Production System.
Lesson 4 – The Toyota Production System House
  • The Toyota Production System House
Lesson 5 – The Five Critical Improvement Concepts
  • Discuss five key ideas supporting Lean process improvement: value, waste, variation, complexity, and continuous improvement.
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.
Lesson 7 – Types of Waste
  • In this session, participants learn about the three primary wastes (muda, muri, and mura) and some new types.
Lesson 8 – Creating a Lean Enterprise
  • Explore some ways to create an environmentally friendly organization with Lean. Learn about the 20 keys to a Lean organization.
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.
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.
Lesson 11 – Lean Thinking Tools
  • Learn about some Lean thinking tools, including 5W-2H, Genchi Genbutsu, Gemba, and 5-S.
Lesson 12 – Kaizen Events
  • This session will cover the five levels of Kaizen events, focusing on Level 3 (the Kaizen blitz).
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.
Lesson 14 – A Plan to Take Home
  • The final session will challenge participants to think about roadblocks and pitfalls to Lean implementation and bring those lessons to their organization. Participants will also be given some ideas for Lean projects and a framework for a successful Lean approach.
Lesson 15 – Workshop Wrap-Up
  • Participants will have an opportunity to ask questions and fill out an action plan

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