The Fundamentals of Lean Course
Start With a Comprehensive Foundation
Learn to see both “the tree and the forest,” understanding the big and small picture concepts of a lean thinking organization. Diagnose your situation holistically. Identify the most pressing cultural and technical gaps within your organization.
Develop Capable Lean Leaders
Build awareness and capability within all levels of your management team. Make lean the responsibility of the many and not the few!
Align your Management Team
Establish common language and standard tools for practicing and learning lean. Bring everyone together to support your most pressing goals and objectives.
Included in this Course
Deliver Training on Your Terms
- Introduction to the course structure, content, and navigation.
- Instructions for support and asking questions.
What is Lean?
- Discover three perspectives to describe what lean is all about.
- Understand the role of scientific thinking in the origins and practice of lean.
- Learn four tips to help set you up for success learning lean.
The Lean House
- Understand a simple version of the “lean house,” for the sake of organizing what you lean about lean.
Value & Waste
- Learn how to define and identify “value” and “waste.”
- Discover the three M’s: muri, mura, and muda.
- Survey each of the 7 wastes of lean.
- Realize how lean methods approach cost reduction differently than conventional approaches.
- Learn the “Four Ms” of stability: man, machine, material, and method.
- Discover common factors that create instability in each category.
- Realize how stability is a prerequisite to standardization and continuous improvement.
- Define “standard work” and discover how it is much more than SOPs.
- Learn the many ingredients that are composed into a standard work “recipe.”
- Overview four common types of standard work: 8-step-process, classic standardized work, TWI Job Instruction, and video.
- Discover four reasons why standard work is critical to your success.
- Learn the two primary purposes of 5S.
- Overview each of the five disciplines of 5S: sort, set in order, shine, standardize, and sustain.
- Discover the big picture as to why 5S matters.
- Define kaizen (continuous improvement) and discover its origins.
- Appreciate how kaizen is both a culture creating of small improvements, and also big improvements.
- Discover how 80% of your potential depends on kaizen by front-line associates.
- Overview how to run larger kaizen as an event.
- Discover what heijunka (production leveling) is all about.
- Learn why production leveling matters to the stability and efficiency of your organization.
- Understand production leveling conceptually via a scheduling example, and the role of schedule mixing and pattern production.
- Understand visual management through strong 5S controls, and also “expected vs. actual” performance.
- Survey common visual control boards: production tracking (hour-over-hour) chart, monthly tracking chart, job-by-job tracking chart, and a task completion board.
- Realize how these simple controls are essential to the success of lean management and PDCA/scientific thinking.
- Define “flow” and the concept of “just-in-time” (JIT) manufacturing.
- Explore the consequences of batch size as it relates to lead time and performance metrics.
- Learn how continuous flow produces better quality, reduced inventory, and faster feedback.
- Survey how to create balanced workcells with flexible manpower and one-piece flow.
- Define takt time and understand how it limits over production, creating steady flow.
- Learn how takt time limits overburden and unneveness.
- Learn how to calculate takt time based on customer demand.
- Define a pull system along with the term “kanban.”
- Survey common pull systems including: one-piece-flow, FIFO, kanban supermarket, 1-card kanban, and 2 bin kanban systems.
- Compare and contrast the movement of material in push vs. pull systems.
- Understand what SMED is and why quick changeovers and critical to achieving leveled production and steady flow.
- Learn a simple 5-step approach to achieving shorter changeover times.
- Discover the importance of moving internal activities to external activities.
Value Stream Mapping
- Define a “value stream” and overview value stream mapping as a tool for continuous improvement.
- See an example of VSM in terms of a current state and future state map.
- Define “jidoka” and learn how to create smart automation with quality built-in.
- Understand key jidoka concepts including: a culture of “stop and fix problems,” built-in quality, separation of man & machine, poka yoke, and andon.
- Learn the value of multi-process handling,
- Learn the two types of problems.
- Overview characteristics of effective problem-solving.
- Learn to connect problem-solving to the bigger picture with measurable impact.
- Survey common problem-solving tools: graphs/charts, fishbone diagrams, check sheets, control charts, histograms, and pareto charts.
- Understand the role of PDCA in effective problem-solving.
- Discover the critical ways in which lean management differs from traditional management.
- Learn the three lean management practices to create a lean culture.
- Overview how lean management is often structured vs. traditional organizational structures.
- Realize the important role of the team leader.
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