Lean Process Improvement Training Course

Lean Process Improvement Training Course


Event outline

Course Overview

Lean process improvement is a system of steps that help organisations reduce waste by focusing on customer value. By identifying how customer value flows across every aspect of the organisation, management & teams can then fine-tune and implement processes that create zero waste.

The pd training Lean Process Improvement Training course will enable teams with the right tools to implement lean principles of process improvement into the very core of their culture, reducing waste and improving product and service value to the customer. Tools covered include 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu.

Learning Outcomes

  • Gain an understanding of Lean
  • Describe "The Toyota Production System" and TPS house.
  • Master the five lean principles
  • Learn how to categorise products or systems into the three groups
  • Learn how to create and contribute to a lean enterprise
  • Identify and reduce various types of waste
  • Learn to create a plan for an organisation that's more environmentally Lean
  • Learn how to implement & evaluate Lean changes with PDSA cycle R-DMAIC-S models
  • Learn how to effectively use lean thinking frameworks like 5W-2H, Genchi Genbutsu, Gemba, and 5-S
  • Prepare for and complete a basic 5-S
  • Learn the five levels of Kaizen events, particularly a Kaizen blitz
  • Effective tips for data gathering, mapping and analysis using flow charts, Ishikawa and SIPOC diagrams, and value stream maps
  • Create a successful plan for a lean project

Course Outline

Day One:

Lesson 1: Understanding Lean

  • Participants will learn what Lean is and what its origins are. This session will explore the Toyota Precepts, how Lean differs from Six Sigma, and some common Lean terms.

Lesson 2: The Toyota Production System

  • Participants will learn about the Toyota Production System House.
  • Discover an alternate representation of the Toyota Production System.

Lesson 3: The Five Critical Improvement Concepts

  • Discuss five key ideas supporting Lean process improvement: value, waste, variation, complexity, and continuous improvement.

Lesson 4: Understanding Value with the Kano Model

  • This session will explore value with the Kano model, which divides product or system characteristics into three groups: basic, performance, and value added.

Lesson 5: Types of Waste

  • In this session participants learn about the three main wastes (muda, muri, and mura) as well as some new types.

Lesson 6: Creating a Lean Enterprise

  • Explore some ways to create an environmentally friendly organisation with Lean. Learn about the 20 keys to a Lean organisation.

Day two:

Lesson 7: The Plan, Do, Study, Act (PDSA) Cycle

  • The first session of Day Two will cover the PDSA cycle, which should be used to plan and implement organisational changes.

Lesson 8: Using the R-DMAIC-S Model

  • This session will cover the Recognise - Define - Measure - Analyse - Improve - Control – Sustain model, an advanced version of PDSA primarily used in Six Sigma.

Lesson 9: Lean Thinking Tools

  • Learn about some Lean thinking tools, including 5W-2H, Genchi Genbutsu, Gemba, and 5-S.

Lesson 10: Kaizen Events

  • This session will cover the five levels of Kaizen events, with a focus on Level 3 (the Kaizen blitz).

Lesson 11: Data Gathering and Mapping

  • Most of the second afternoon will be spent learning about and practicing various Lean data tools, including flow charts, Ishikawa (cause and effect or fishbone) diagrams, SIPOC charts, and value stream maps. We will also share some tips for effective data analysis.

Lesson 12: A Plan to Take Home

  • The final session will challenge participants to think about roadblocks and pitfalls to Lean implementation and how to bring those lessons to their organisation. Participants will also be given some ideas for Lean projects and a framework for a successful Lean approach.

Workshop Wrap-Up

  • Participants will have an opportunity to ask questions and fill out an action plan

Dates & registration

There are no dates listed for this event.

Provider information

pd training is an Australian-owned, international training and professional development and services organisation, with approximately 400 specialist trainers across Australia, delivering thousands of courses each year in our 16 areas of specialty.