Lean Fundamentals

Course Outline

Introduction to Lean
High-level overview of what Lean is, review the Lean Mental Model, discuss the different roles in building a continuous improvement culture and provide a brief introduction to the DMAIC Model.

Legoliv
Hands-on activity to highlight the following key Lean Tools: Standard Work, 5S, SMED, Pull System, Heijunka, and Takt Time.

Employee Engagement
Focus is on building a continuous improvement culture that engages all employees and an overview of some Kaizen Suggestion Systems

8 Forms of Waste
Waste is any action or step in a process that does not add value to the customer. Lean thinking aims to remove wastes from work processes. This overview will define waste and the 8 different forms.

Value Stream Mapping and Process Focus
Value stream mapping is a Lean manufacturing technique to analyze, design, and manage the flow of materials and information required to bring a product to a customer. Also known as “material and information-flow mapping”, it uses a system of standard symbols to depict various work streams and information flows.

5S
5S is a workplace organization tool that consists of the following: Sort, Set in Order, Shine, Standardize and Sustain. This overview will walk through each “S” and provide examples.

Understanding our Customers and Processes
To understand which processes need improvement, we need to understand what our customers expect, how our processes are performing today, and where the gaps to performance are. This session will review some tools to help us do that.

Project Selection and Scoping
This session will focus on Project Selection and Scoping which is one of the first steps in addressing a problem.

Root Cause Analysis
This session will focus on gaining a better understanding of driving to root cause. We will deep dive on tools such as:

• 5 Why and
• Cause and effect

Data Analysis
This session will focus on the importance of data collection, the different types of data, and how best to measure it.

Standards
This session will focus on the importance of standards that allow us to set today’s best practice and stabilize the process.

Statistical Process Control (SPC)
This session will discuss the impact of variation and how to describe it numerically and graphically. In addition, we’ll understand some basic tools used to monitor the process performance. Note: This is just a basic course, not a deep dive into the topic which is typically delivered in Six Sigma Green Belt training.

Tiered Management
This session will review the definition of a Tiered Management System, how to set up the structure, and walk through some examples.