Origins of Lean
Roles of Leaders, Teams and Coaches
Principles of Lean.
How Lean Works
Easy to see work and problems.
Label and outline
Set, measure and review KPIs.
Show status and performance.
Best-known way to work.
SIPORC, process map, Subject-Verb-Direct Object
SOPs, Work Instructions
Forms and Checklists
Definition of value and different types of waste (required and purely non-value-adding).
3 Types of Wastes
Muda – not adding value
Mura – unevenness
Muri – overburden
Review of 9 types of Muda waste
Prevent mistakes from occurring
Prevent mistakes from becoming defects
Prevent defects from becoming failures
Simple and low cost methods
Failure Mode and Effect Analysis
In response to Customer pull
Reduce batch size.
Level the load
Use Kanban to connect.
Cycle, Span, Touch, Takt Time
Do not blame people; do not fight fires; prevent problems.
Plan, Do, Check, Act (PDCA) cycle
Determine and address root causes; ask Why? 5 times
Small (CI), Medium (A3, Toyota Kata) and Large (Team, DMAIC)
Win friends & influence people
Bringing out the best in people
Ask 3 Questions
Daily Stand-Up Meetings
Lean Leadership – what is a Lean Leader, and what does a Lean Leader need to do
Empower People to solve problems to improve processes to increase performance to lead to greater prosperity.
The importance of trying new things
Free online resources (including LSS Council)
Request for participants fill survey. (generally filled in after the training)
Explanation of the exam. This is an individual, closed book, 1-hour exam, which means students are asked to do the exam only from memory and without notes or materials of any sort.
One DMAIC project or a collection of smaller improvements with measured impact demonstrating understanding of and successful application of the concepts and tools learned in the training.