Overview
Lean principles have come a long way over the past 300 years. From Benjamin Franklins early ideas, to Henry Ford’s work in the 1920’s and the Toyoda precepts in the 1930’s, to Jeffery Liker’s publication of The Toyota Way in 2004, Lean processes have evolved from a simple concept to a set of widely used best practices.
This course will give you the foundation to begin implementing Lean process improvement tools in their workplace. The first part of the course explores the foundations of Lean through the Toyota precepts and the five critical improvement concepts (value, waste, variation, complexity, and continuous improvement). The second part of the course will give you the tools to perform continuous improvement in their organization, including 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu, and various Lean data mapping methods.
Learning Outcomes
After you complete this course, you will be able to:
- Define Lean and its key terms
- Describe the Toyota Production System and the TPS house
- Describe the five critical improvement concepts
- Use the Kano model to understand, describe, analyze, and improve value
- Identify and reduce various types of waste
- Create a plan for a more environmentally Lean organization
- Use the PDSA and R-DMAIC-S models to plan, execute, and evaluate Lean changes
- Use Lean thinking frameworks, including 5W-2H, Genchi Genbutsu and Gemba
- Prepare for and complete a basic 5-S
- Describe the key elements of Kaizen events, particularly a Kaizen blitz
- Gather, analyze, and interpret data using flow charts, Ishikawa (fishbone) diagrams, SIPOC diagrams, and value stream maps
- Go back to your organization with a plan to begin incorporating Lean into your corporate culture
Course Outline
- 2.1: Defining Lean
- 2.2: The History of Lean
- 2.3: Lean vs. Six Sigma
- 2.4: Pre-Assignment Review
- 2.5: A Lean Glossary
- 3.1: Overview of the Liker Pyramid
- 3.2: Exploring the Philosophy
- 3.3: Considering the Processes
- 3.4: Understanding People and Partners
- 3.5: Problem Solving Tools
- 5.1: Key Ideas
- 5.2: Case Study
- 7.1: The Three Categories
- 7.2: Making Connections
- 8.1: Going Green with Lean
- 8.2: The Characteristics of a Lean Organization
- 11.1: 5W-2H
- 11.2: Genchi Genbutsu and Gemba
- 11.3: Performing a 5-S
- 12.1: About Kaizen and Kaizen Events
- 12.2: Typical Kaizen Blitz Workflow
- 12.3: Personal Reflection
- 13.1: Flow Charts
- 13.2: Making Breakfast
- 13.3: Ishikawa (Cause and Effect) Diagrams
- 13.4: SIPOC Diagrams
- 13.5: Value Stream Maps
- 13.6: Tips for Effective Data Analysis
- 14.1: Roadblocks and Pitfalls
- 14.2: Creating a Successful Organizational Structure
- 14.3: Where to Get Started?
- 14.4: A Plan for Success
