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Lean Process Improvement

This course is currently available as E-Learning, or a private instructor-led class scheduled to suit your availabilty. You can click here to inquire further or you ask us for recommendations on similar classes.

Recommended Prerequisites

No prerequisites are required for this course.

Course Overview

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 course will give participants the foundation to begin implementing Lean process improvement tools in their workplace. The first part of the course 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 part of the course 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.

Learning Objectives

Course Outline

  1. Course Overview
  2. Understanding Lean
  3. Defining Lean
  4. The History of Lean
  5. Lean vs. Six Sigma
  6. Pre-Assignment Review
  7. A Lean Glossary
  8. The Toyota Production System
  9. Overview of the Liker Pyramid
  10. Exploring the Philosophy
  11. Considering the Processes
  12. Understanding People and Partners
  13. Problem Solving Tools
  14. The Toyota Production System House
  15. The Five Critical Improvement Concepts
  16. Key Ideas
  17. Case Study
  18. Understanding Value with the Kano Model
  19. Types of Waste
  20. The Three Categories
  21. Making Connections
  22. Creating a Lean Enterprise
  23. Going Green with Lean
  24. The Characteristics of a Lean Organization
  25. The Plan, Do, Study, Act (PDSA) Cycle
  26. Using the R-DMAIC-S Model
  27. Lean Thinking Tools
  28. 5W-2H
  29. Genchi Genbutsu and Gemba
  30. Performing a 5-S
  31. Kaizen Events
  32. About Kaizen and Kaizen Events
  33. Typical Kaizen Blitz Workflow
  34. Personal Reflection
  35. Data Gathering and Mapping
  36. Flow Charts
  37. Making Breakfast
  38. Ishikawa (Cause and Effect) Diagrams
  39. SIPOC Diagrams
  40. Value Stream Maps
  41. Tips for Effective Data Analysis
  42. A Plan to Take Home
  43. Roadblocks and Pitfalls
  44. Creating a Successful Organizational Structure
  45. Where To Get Started?
  46. A Plan for Success
  47. Personal Action Plan
  48. Recommended Reading List
  49. Post-Course Assessment

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