Lean is a systematic approach to identifying and eliminating the eight wastes-considered non-value-adding activities-through continuous improvement by flowing the product completely at the pull of the customer. The eight wastes are: waiting, defects, extra processing, inventory, excessive motion, transportation, over production, and underutilized employees.

Certification:

Upon completion of this four-day program, attendees can submit a project for a Lean Agent certification.

What You'll Learn

• Lean concepts and tools and how they apply to all types of processes and industries
• Use Lean methods and data to reduce costs, shorten cycle times, expand capacity, and improve productivity
• How Lean and Six Sigma are highly complementary
• Difference between successfully instilling Lean Thinking and running the next "Flavor of the Month" program
• Get input from knowledgeable instructors regarding specific concerns and projects to start on a proven path to success

Who Needs to Attend

All types of service and manufacturing organizations that experience the following challenges:

• Missed order dates
• High product or service cost relative to the competition
• Losing market share due to increased delivery time or cost problems
• Limited production capacity - space is used by inventory

• Lean concepts and tools and how they apply to all types of processes and industries
• Use Lean methods and data to reduce costs, shorten cycle times, expand capacity, and improve productivity
• How Lean and Six Sigma are highly complementary
• Difference between successfully instilling Lean Thinking and running the next "Flavor of the Monthprogram
• Get input from knowledgeable instructors regarding specific concerns and projects to start on a proven path to success

Prerequisites

There are no prerequisites for this course.

Follow-On Courses

• Six Sigma Green Belt or Black Belt certification programs

Course Outline

1. Introduction

• Course Overview
• Introduction to Lean
• Linkage to Six Sigma

2. Lean Mentality: Muda (Waste) Elimination

• The Hidden Office/Factory
• Seven Types of Waste
• Eliminating Waste

3. Mapping the Value Stream

• Value Stream Mapping
• Different Types of Maps
• Foundation for Lean Eents

4. Lean Events

• Kaizen
• Running a Typical Five Day (or Shorter) Event

5. Constraints

• Finding the "Bottlenecksin a Process Flow

6. Flow and TAKT Time

• Movement Through the Value Stream
• Rate or Rhythm of Flow Through each Process

7. Pull Systems and Kanban

• All Activity is "Pulledby Customer Demand
• Simple Visual Signals

8. 5S Implementation

• A Systematic Approach to Organizing the Work Space
• NOT Just Housekeeping!

9. Poka Yoke (Mistake Proofing)

• Reducing the Opportunity for Human Errors to Affect the Process

10. Lean Management Principles

• How to Make it Happen and Make it Last in an Organization

11. Job Instruction Training

• Transferring Knowledge in a Quality Process