Topic 1

Course Overview

• Course Objectives

Topic 2

Understanding Lean

• Participants will learn what Lean is and what its origins are. This session will explore the Toyota Precepts, how Lean differs from Six Sigma, and some common Lean terms.

Topic 3

The Toyota Production System

• Participants will learn about the Toyota Production System House. Discover an alternate representation of the Toyota Production System.

Topic 4

The Toyota Production System House

• The Toyota Production System House

Topic 5

The Five Critical Improvement Concepts

• Discuss five key ideas supporting Lean process improvement: value, waste, variation, complexity, and continuous improvement.

Topic 6

Understanding Value with the Kano Model

• This session will explore value with the Kano model, which divides product or system characteristics into three groups: basic, performance, and value added.

Topic 7

Types of Waste

• In this session participants learn about the three main wastes (muda, muri, and mura) as well as some new types.

Topic 8

Creating a Lean Enterprise

• Explore some ways to create an environmentally friendly organization with Lean. Learn about the 20 keys to a Lean organization.

Topic 9

The Plan, Do, Study, Act (PDSA) Cycle

• The first session of Day Two will cover the PDSA cycle, which should be used to plan and implement organizational changes.

Topic 10

Using the R-DMAIC-S Model

• This session will cover the Recognize – Define – Measure – Analyze – Improve – Control – Sustain model, an advanced version of PDSA primarily used in Six Sigma.

Topic 11

Lean Thinking Tools

• Learn about some Lean thinking tools, including 5W-2H, Genchi Genbutsu, Gemba, and 5-S.

Topic 12

Kaizen Events

• This session will cover the five levels of Kaizen events, with a focus on Level 3 (the Kaizen blitz).

Topic 13

Data Gathering and Mapping

• Most of the second afternoon will be spent learning about and practicing various Lean data tools, including flow charts, Ishikawa (cause and effect or fishbone) diagrams, SIPOC charts, and value stream maps. We will also share some tips for effective data analysis.

Topic 14

A Plan to Take Home

• The final session will challenge participants to think about roadblocks and pitfalls to Lean implementation and how to bring those lessons to their organization. Participants will also be given some ideas for Lean projects and a framework for a successful Lean approach.

Topic 15

Workshop Wrap-Up

• Participants will have an opportunity to ask questions and fill out an action plan