Lean Processes and Tools

Introduction

Lean thinking is based on the legendary Toyota Production System that produces very high quality products; in a very short time and at a low cost. To many people and organisations achieving all three of these goals simultaneously is an impossibility. Lean provides a methodology and tools that enable organisations to make significant improvements in lead time, cost reduction and product or service quality. This course provides delegates with a practical introduction to the lean methods and tools so that they can undertake simpler improvement activities.

Objectives

This three day course uses a blend of theory and practical exercises. During the course delegates will develop an understanding of:

• The key elements of the Lean thinking and methodology
• Voice of the customer; customer value and the value stream
• The identification (learning to see) and elimination of waste in processes
• The main lean tools and techniques and their practical application.

Course Content

• Introduction to Lean thinking
• Determining lean metrics
• Approaches to quality and process improvement
• Identifying waste (learning to see)
• DMAIC methodology
• Root cause analysis tools
• Lean Project Charter
• 5S, mistake proofing and visibility principles
• Voice of the customer and customer value
• Push versus pull and kanbans
• Process flow diagrams
• Set-up reduction, SMED
• Value stream mapping—current state
• Standard work,
• Lean measurement
• Workload balance and takt time
• Operational definitions
• Brain storming techniques and evaluation
• Data collection
• Future state value stream map
• Analyse current state
• Improvement action plan
• Measuring and sustaining the gain
• Ownership reward and recognition

Who should attend?

All staff wishing to understand how Lean thinking and lean tools can be used to deliver process improvement projects in the work place. There are no prerequisites for this course except a willingness to participate and an open mind.

Follow on courses

Value Stream Mapping (2 days) or Lean Six Sigma Green Belt (5 days)