
COURSE OVERVIEW
Lean principles have come a long way over the past 300 years. From Benjamin Franklin’s 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 participants the foundation to begin implementing Lean process improvement tools in their workplace. The first part of the course will explore 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 participants tools to perform continuous improvement in their organization, including 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu, and various Lean data mapping methods.

LEARNING OBJECTIVES
- 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
- Course Overview
- Understanding Lean
- Defining Lean
- The History of Lean
- Lean vs. Six Sigma
- Pre-Assignment Review
- A Lean Glossary
- The Toyota Production System
- Overview of the Liker Pyramid
- Exploring the Philosophy
- Considering the Processes
- Understanding People and Partners
- Problem Solving Tools
- The Toyota Production System House
- The Five Critical Improvement Concepts
- Key Ideas
- Case Study
- Understanding Value with the Kano Model
- Types of Waste
- The Three Categories
- Making Connections
- Creating a Lean Enterprise
- Going Green with Lean
- The Characteristics of a Lean Organization
- The Plan, Do, Study, Act (PDSA) Cycle
- Using the R-DMAIC-S Model
- Lean Thinking Tools
- 5W-2H
- Genchi Genbutsu and Gemba
- Performing a 5-S
- Kaizen Events
- About Kaizen and Kaizen
- Events Typical Kaizen Blitz
- Workflow Personal Reflection
- Data Gathering and Mapping
- Flow Charts
- Making Breakfast
- Ishikawa (Cause and Effect)
- Diagrams
- SIPOC Diagrams
- Value Stream Maps
- Tips for Effective Data Analysis
- A Plan to Take Home
- Roadblocks and Pitfalls
- Creating a Successful
- Organizational Structure
- Where to Get Started?
- A Plan for Success
- Personal Action Plan
- Recommended Reading List
- Post-Course Assessment