Lean Process Improvement

Lean Process Improvement involves perfecting processes by working smarter to minimize waste within a company. Although Lean process analysis has emerged as a ‘best business practice’ in recent years, it’s organized around a culture of ideas, tools, and processes that have existed among the best business practitioners for hundreds of years.

Based on leading research and presented in a format that is straightforward and easily understood, students learn the foundation necessary to begin using Lean process improvement tools in their workplace.

This useful skillset includes Toyota’s five critical improvement concepts, tools needed to continuously improve an organization (5S, PDSA, DMAIC, Kaizen, various Lean data mapping methods), and more.

Course Topics:

Session One: Course Overview

Session Two: Understanding Lean

• Defining Lean
• The History of Lean
• Lean vs. Six Sigma
• Pre-Assignment Review
• A Lean Glossary

Session Three: The Toyota Production System

• Overview of the Liker Pyramid
• Exploring the Philosophy
• Considering the Processes
• Understanding People and Partners
• Problem Solving Tools

Session Four: The Toyota Production System House

Session Five: The Five Critical Improvement Concepts

• Key Ideas
• Case Study

Session Six: Understanding Value with the Kano Model

Session Seven: Types of Waste

• The Three Categories
• Making Connections

Session Eight: Creating a Lean Enterprise

• Going Green with Lean
• The Characteristics of a Lean Organization

Session Nine: The Plan, Do, Study, Act (PDSA) Cycle

Session Ten: Using the R-DMAIC-S Model

Session Eleven: Lean Thinking Tools

• 5W-2H
• Genchi Genbutsu and Gemba
• Performing a 5-S

Session Twelve: Kaizen Events

• About Kaizen and Kaizen Events
• Typical Kaizen Blitz Workflow
• Personal Reflection

Session Thirteen: Data Gathering and Mapping

• Flow Charts
• Making Breakfast
• Ishikawa (Cause and Effect) Diagrams
• SIPOC Diagrams
• Value Stream Maps
• Tips for Effective Data Analysis

Session Fourteen: A Plan to Take Home

• Roadblocks and Pitfalls
• Creating a Successful Organizational Structure
• Where To Get Started?
• A Plan for Success
• Recommended Reading List
• Personal Action Plan