Course Methodology

This course will engage participants in various simple and complex Lean exercises. The course will challenge participants through Lean tools such as Value stream mapping, 5S, and case studies. Lectures, group discussions, and presentations will be used to achieve the learning objectives.

Course Objectives

By the end of the course, participants will be able to:

• Explain the history and concepts of Lean and its importance for organizations
• Appraise Lean components, typical process waste, and how Lean tools can directly address eliminating or reducing operating costs, cycle time, and non-value-added activities
• Contrast Six Sigma methodology and Lean practices
• Define how to measure Lean deployment in organizations
• Outline an effective Lean implementation plan

Target Audience

All professionals involved in hands-on initiatives focusing on operations excellence and improving speed and those responsible for linking, measuring, and improving the organization's performance.

Target Competencies

• Acquiring a Lean mindset
• Value stream mapping
• Deploying Six Sigma
• Results orientation
• Managing change

Introduction to Lean Thinking and its History

• Aligning organizational strategy with lean principles
• Lean core concepts
• History of Lean
• Operational excellence and Lean
• Benefits of Lean
• Five Lean principles
• The 8 types of waste, and waste elimination strategies

Lean Components and Tools, Part I

• Building blocks of Lean
• Quality Function Deployment (QFD)
• Hoshin Kanri
• SIPOC tool
• Value Stream Mapping (VSM)
• 5S program
• Point Of Use Storage (POUS)
• Visual Management
• Quick changeover or Single-Minute Exchange of Dies (SMED)

Lean Components and Tools, Part II

• Standard work
• Cellular layout
• Spaghetti diagrams
• Kanban and pull systems
• One-piece flow
• Poka-yoke 
• Total productive maintenance

Lean and Six Sigma: A One-Two Punch

• A little Six Sigma story
• What is Six Sigma?
• The DMAIC methodology
• Understanding process capability
• Six Sigma and Lean common interests
• Comparison of Lean and Six Sigma approaches

 Lean Measurement

• What is a Key Performance Indicator (KPI)?
• Metrics versus KPIs
• Developing your Lean KPIs
• Output versus outcome
• Obstacles to measurement
• Measurement of Lean within a Balanced Scorecard

Lean Implementation Road Map

• Creating a Lean culture  
• Lean deployment roadmap
• The Lean leadership paradigm
• Building your Lean implementation plan
• Barriers to Lean
• The SCORE implementation methodology by BMGI