Module 1 – Intensive Lean Principles and Lean Tools Training
•Lean Principles and Lean Thinking Deployment
•Waste Identification and Elimination
•Selection of Product Families and Value Streams
•Organising Operations to meet the Customer Demand Rate
•Use of Buffer and Safety Resources or Stock, Finish Goods Supermarket Strategy, Organizing the Workspace for Better Productivity (5S)
•The Relationship between Quality and Turnaround Time, the Lean Quality Approach
•Making Processes Flow
•Implementing Continuous Flow, Balancing Work and Work Area Re-Design
•Maximising Use of Equipment Results in Overproduction, the Benefits of Pull Versus Push System
•FIFO Processing, Fixed Length Pipes, Surfacing Issues, Reducing Setup Times and Interruptions
•Signaling Systems, Immediate Feedback and Planned Flexing, Setup Time Reduction
•Why Level Demand, How to Level the Mix and Supply Intake, Establishing an Interval (EPEI)
•The Use of Visual Management and Why Use Immediate Feedback
•Organising for Rapid Projects
Module 2 – Practical Value Stream Mapping
•Introduction to Organisational Value, Waste, Value adding and non-value adding activities
•Application of Value Stream Mapping in Waste Identification and Lean Implementation
•Overview of Value Stream Mapping Principles and Methodology
•Mapping tools and symbols
•Value stream mapping – Current State
•Hands-on Mapping Session
•Analysing the Current State
•Value Stream Mapping – Future State
•Hands-on Mapping Session
•Achieving the Future State
•Using Value Stream Maps to Identify Lean Improvement Projects
•Prioritising and Selecting Lean Projects
•Developing a Lean Roadmap
Module 3 – Kaizen Event Implementation
•Identify the pilot project for the Kaizen Event
•Provide consultancy on project structure
•Provide guidance on Kaizen Event preparation
•Agree on objectives / Analyse background data / Map Current State for selected event
•Identify areas for improvement / Map Future State for each selected Event
•Implement Future State improvements
•Evaluate performance for Future State
•Finalise improvements and on-going actions / Feedback
•Post event review to ensure momentum has been maintained
•Follow up to ensure project completion
•Identify further areas for improvement / skills development
Module 4 – Final Assessment
•Project Presentation
•Examination
