Lean Online Training Modules

Lean Online Training Modules

A Lean operation produces just what is needed, when it is needed with no additional labor, costs, inventory, or time. Learn the skills necessary to apply Lean techniques to reduce waste and improve process efficiency. Gain a practical understanding of Lean continuous improvement techniques and how to use them to reduce errors, inventory, and production lead time. This module will:

• Define Lean, its importance, benefits, and objectives.
• Describe Lean tools, methodologies, and levels of deployment.
• Identify the roles and responsibilities of the Lean implementation team.
• Discuss how these roles can be integrated into an organization.

Introduction to Lean Office and Service

In the office and service environments, Lean improvement activities focus on eliminating waste and speeding up the process. This is accomplished by eliminating idle time, bureaucracy, and unnecessary redundancy. Lean Office and Service also helps organizations understand and predict changes in customer expectations, thereby enabling them to react quickly to meet customer needs. This module will:

• Discuss why Lean Office and Service is important to an organization’s long-term success.
• Discuss common obstacles organizations face when implementing Lean Office and Service and how to overcome them.
• Discuss the relationship between some important Lean tools, including process mapping, service family matrixes, and Value Stream Analysis, and demonstrate how to apply them.

Eight Wastes

Producing anything that the customer doesn’t want or need is waste. It lowers your profits and leaves you less competitive in your market. Learn about the waste that is hidden, or taken for granted, in both manufacturing and office environments. Utilizing Lean techniques can help to dramatically reduce these wastes and their associated costs. This module will:

• Describe Value Add versus Non-Value Add activities and explain why they are important in a Lean implementation.
• Identify the Eight Wastes and discuss why they are a primary focus during Lean implementation.
• Describe each of the Eight Wastes in detail and give examples.

5s

5S is a technique that results in a workplace that is clean, uncluttered, safe, and well organized. The 5S pillars provide a methodology for organizing, cleaning, developing, and sustaining a productive work environment. A 5S environment has “a place for everything and everything in its place,” with all tools and materials ready where and when they are needed. Learn how 5S can help reduce waste and optimize productivity in any work environment. This module will:

• Discuss 5S and describe its overall purpose and benefits, and identify the five phases of its process.
• For each phase, drill down to discuss key objectives, tools or methods used to reach those objectives, and the benefits achieved.
• Introduce a sixth “S,” Safety.

Current Value Stream Mapping

Value Stream Mapping is an essential planning tool used to identify improvements that will result in a Lean Value Stream. The first step is to create the Current State map, showing the Value Stream of a particular product or service. This module will:

• Define Value Stream and Product Family.
• Explain how to identify Product Families from groups of products.
• Describe a Current State Value Stream Map and discuss its purpose.
• Walk through the steps of creating a Current State Value Stream Map.
• Identify commonly used symbols; and describe how metrics are collected and represented.

Future Value Stream Mapping

The goal of a Lean Value Stream is to produce the product or complete the process in the shortest Lead Time, at the highest quality and at the lowest cost possible, in order to deliver the highest level of customer satisfaction. After the Current State Value Stream Map has been created, the next step is to analyze the current process and flow to develop a clear vision of the desired Future State. In order for an organization to complete its Lean transformation process, it must understand the desired end goal. This module will:

• Define a Future State Value Stream Map and describe its purpose.
• Define and calculate Takt Time, and discuss its role in Value Stream Mapping.
• Demonstrate how to analyze a Current State Value Stream Map to create a Future State Value Stream Map.
• Discuss how to enable flow and develop Pull.

A3 Problem Solving

A3 Problem Solving is a means of capturing all stages of a problem – identification, analysis, review, solution planning, and project management – on one A3 sized (11″x17″) piece of paper. A3 Problem Solving facilitates visual tracking of a project. This module will:

• Show the importance of observation for Lean process improvement;
• Describe the A3 Report as a problem-solving and communication tool;
• Demonstrate how the Plan-Do-Check-Act, or PDCA, cycle is an integral part of A3;
• Explain the concept of Going to Gemba.
• Walk through the steps for completing an A3 Report, including key questions to ask at each stage.
• Discuss what makes a good A3.

Introduction to Theory of Constraints

The Theory of Constraints (TOC) is a system improvement philosophy developed by Dr. Eliyahu M. Goldratt. TOC explains that the three ways for a company to make money are by reducing operating expenses, reducing inventory, and increasing throughput. This module will:

• Discuss the origins of the Theory of Constraints.
• Examine its philosophy and governing principles.
• Describe its applications.
• Walk through its Five Focusing Steps.
• Study some examples, and review typical results.
• Examine the relationship between the Theory of Constraints and Critical Chain Program Management

Kaizen Event

Kaizen Events are highly effective team events that focus on achieving rapid results. Kaizen teams use various analytical and Lean techniques, such as Value Stream Mapping, Changeover Reduction, 5S, Total Productive Maintenance, and Workplace Design to implement rapid improvements. This module will:

• Define Kaizen Event and discuss its purpose and application.
• Explain how Kaizen Events can provide rapid business benefits and accelerate the execution of larger initiatives.
• Walk you through the structured approach for running Kaizen Events, in both office and manufacturing processes.

Visual Management

Visual Management is the establishment of a workplace where performance conditions can be understood by sight. Problem areas are highlighted so employees can take immediate action to eliminate waste. One of the most important benefits of a visual workplace is that even someone unfamiliar with the process can see what is happening, identify errors, and tell if anything is out of place or missing. This module will:

• Define Visual Management and describe its purpose and benefits.
• Introduce the three characteristics of Visual Management – Self Explaining, Self Regulating, and Self Improving – and discuss why they are important.
• Describe the difference between Visual Controls and Visual Displays, giving examples of each

Standard Work

Standard Work is an essential building block of a Lean Enterprise. It helps ensure that each step in the process is clearly defined so that work can be performed repeatedly in the same manner. Variations in processes result in mistakes or other quality problems that require inspection and rework. This module will:

• Define Standard Work from a Lean perspective.
• Discuss its business benefits; explain why it is the basis for improvement.
• Explain how to create, implement, and improve Standard Work for both office and manufacturing processes.

Error Proofing

Error Proofing is used to ensure products and processes are completed correctly the first time. The goal of error proofing is to prevent the occurrence of defects and to ensure that mistakes are detected when they occur. Because people can make mistakes even in inspection, error proofing often relies on mechanisms built into tools or systems that automatically signal when problems occur or prevent the process from continuing until the proper conditions are met. This module will:

• Define Error Proofing from a Lean perspective.
• Describe its business benefits.
• Discuss how it can improve quality and reduce failures and omissions.
• Illustrate the 6-Step error proofing process and how to apply it.
• Explain how to implement Error Proofing for both office and manufacturing processes.

Changeover Reduction

Changeover Reduction is a structured methodology and technique used to reduce the combined amount of set-up and start-up time it takes to change a process from running one product to running the next one It is one of the fundamental techniques in Lean manufacturing and a key to waste reduction. This module will:

• Define Changeover Reduction.
• Provide a brief overview of its origin.
• Discuss its benefits, and explain how it supports and enables Lean waste reduction.
• Define Takt time.
• Distinguish between external and internal work, and discuss the relevance of each.
• Provide a step-by-step guide to implementing a successful Changeover Reduction program.

Workplace Design and Layout

Creating high performance work spaces or manufacturing cells involves much more than moving machines and people closer together. Well designed work places eliminate waste and help to optimize material, people, and information flow. The work flows in alignment with value streams rather than according to functional teams or departments. This module will:

• Describe how Lean Workplace Design differs from traditional approaches.
• Discuss its business benefits.
• Show how it is used to improve quality and reduce lead times.
• Explain how to create effective Workplace Design for office and manufacturing processes.

Flow and Pull Systems

The concept of “Pull” in a Lean office or factory means to respond to the pull, or demand, of the customer. Lean companies design their operations and processes to respond to the ever-changing requirements of customers. This module will:

• Define Continuous or One Piece Flow and the introductory aspects of Pull Systems.
• Explain where to implement Pull Systems.
• Discuss how they enable effective flow of information and materials, and identify which tools are best suited for various office and manufacturing environments.
• Explain how to apply Pull Systems in a comprehensive and systematic way.

Total Productive Maintenance

Total Productive Maintenance (TPM) is a team and shop floor based initiative focused on optimizing the effectiveness of manufacturing equipment. TPM helps workers efficiently care for the equipment and machines they work with, which will reduce costs, including money and space tied up with spare parts inventory. This module will:

• Describe the primary benefits gained from Total Productive Maintenance.
• Identify the four major categories of maintenance.
• Define Overall Equipment Effectiveness.