Fundamentals of Lean Methodology

Intro to Lean

In this module, we lay the foundation for our Lean journey. We define Lean, delve into its origins, and examine its essential components.

Lean Principles

In this module, we delve into the core principles of Lean, which underpin the entire philosophy and form the foundation for Lean thinking and practice.

Part 1. Types of Waste

In this module, we delve deep into the concept of waste, often referred to by the Japanese term "Muda."

Part 2. Recognizing Waste

In this module, you will learn about the 5s methodology and its fundamental principles of Sort, Set in order, Shine, Standardize, and Sustain.

Kaizen

In this module, we explore the definition of Kaizen, the PDCA cycle, Kaizen events, and the vital role of employee involvement.

Part 1. Standard Work

In this module, we delve into the critical aspects of Standard Work, exploring Time Studies, Cycle Time, and Takt Time. We then venture into the practical world with the Gemba Walk and review how to drive Continuous Improvement through Standard Work.

Part 2. Standard Work

In this module, we delve into essential concepts and techniques for process optimization. Our journey will take us through the intricacies of Spaghetti Diagrams, the efficiency of Batch Flow vs. Single Piece Flow, the power of Control Charts, the importance of Standardization, and the art of Change Management.

Visual Management

In this module, we explore a suite of powerful tools and methodologies. These tools are Visual Controls, Andon Systems, Kanban Systems, Visual Workplace Organization, Total Productive Maintenance, Production Boards, and Managing for Daily Improvement.

Part 1. Lean Tools and Techniques

In this module, we introduce the following tools and techniques: (1) Poka-Yoke (Error Proofing), (2) Process Mapping, (3) Hoshin Kanri (Hex Matrix), (4) Fish Bone Diagram, (5) Quadrant Impact Analysis, (6) Action Tracker, and (7) Kaizen Newspaper.

Part 2. Lean Tools and Techniques

In this module, we introduce the following tools and techniques: (1) Work Breakdown Structure (WBS), (2) Total Quality Management (TQM), (3) Pareto Chart, (4) Value Stream Mapping, (5) 5 Whys Analysis, (6) Root Cause Analysis, and (7) Just-In-Time (JIT) Manufacturing.

Teamwork and Collaboration

In this module, we explore the significance of Cross-Functional Teams, Problem-Solving Teams, and Encouraging Employee Input to drive organizational excellence through collective effort and shared responsibility.

Lean Metrics and KPIs

In this module, we explore the critical role of metrics and KPIs in driving continuous improvement. Gain insights into tracking progress and identifying metrics to optimize performance.

Conclusion and Recap

In this concluding session, we recap the key principles and insights gained throughout the course, reinforcing our commitment to continuous improvement.