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.
You will spend the first part of the day getting to know participants and discussing what will take place during the workshop. Students will also have an opportunity to identify their personal learning objectives.
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.
At the end of the course, students will have an opportunity to ask questions and fill out an action plan.