Lean Process Improvement

About Course

The principles of Lean have significantly advanced over the past three centuries. Beginning with the early ideas of Benjamin Franklin, progressing through Henry Ford’s innovations in the 1920s and the Toyoda precepts of the 1930s, and culminating in Jeffery Liker’s 2004 publication, The Toyota Way, Lean methodologies have transformed from a basic concept into a comprehensive set of best practices widely adopted across industries.

This course is designed to provide participants with the essential knowledge needed to start applying Lean process improvement tools in their workplaces. In the first section, the course will delve into the origins of Lean through the Toyoda precepts and examine the five key concepts for improvement: value, waste, variation, complexity, and continuous improvement. The second section will equip participants with practical tools for driving continuous improvement within their organizations, including techniques like 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu, and various Lean data mapping methods.

By the end of this workshop, you will be able to:
Understand and define Lean, including its essential terminology.
Explain the Toyota Production System (TPS) and the structure of the TPS house.
Discuss the five key concepts critical to process improvement.
Apply the Kano model to comprehend, analyze, and enhance value.
Recognize and minimize different types of waste.

Course Content

UNDERSTANDING LEAN
In this session, you will dig in and develop an understanding of what Lean process improvement is about, including its distinguished history.

THE TOYOTA PRODUCTION SYSTEM
In this session, you will explore the Liker Pyramid, engage with some foundational philosophy, and delve into practical problem-solving techniques.

THE TOYOTA PRODUCTION SYSTEM HOUSE
In this session, we will explore the Toyota Production System House, which integrates the principles of Lean methodology with the foundational Toyoda precepts.

THE FIVE CRITICAL IMPROVEMENT CONCEPTS
In this session, we will delve into five key concepts that form the foundation of these ideas: value, waste, variation, complexity, and continuous improvement.

TYPES OF WASTE
In this session, you will explore various types of waste. It's important to recognize that not all waste is identical, and the strategies for reducing it can differ significantly.

CREATING A LEAN ENTERPRISE
In this session, you will understand the characteristics of a Lean organization and how creating a Lean organization can lead to green initiatives.

THE PLAN, DO, STUDY, ACT (PDSA) CYCLE
In this session, you will discover the PDSA cycle and explore how it fits into the larger framework of Lean process improvement.

USING THE R-DMAIC-S MODEL
In this session, you will delve into an advanced application of PDSA using the R-DMAIC-S model.

LEAN THINKING TOOLS
In this session, you will learn about 5W-2H; Genchi Genbutsu and Gemba; and the 5S method, which stands for sort, shine, straighten, standardize, and sustain.

DATA GATHERING AND MAPPING
In this session, students will be introduced to data gathering and mapping through tools such as flowcharts, cause and effect diagrams, SIPOC, and value stream maps.

LEAN PROCESS IMPROVEMENT QUIZ
The quiz on Lean process improvement tests participants' understanding of the key concepts, including value, waste, variation, complexity, and continuous improvement. It also assesses knowledge of practical Lean tools such as 5S, Kaizen, PDSA, DMAIC, and data mapping methods.

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