Essentials of Lean Process Improvement

4-Day Boot Camp Certificate Program

Critical Tools for Lean Times

In today’s challenging business environment, it is imperative that companies slash cost and cycle/service time without cutting customer value, lest they create a death spiral of shrinking revenue. Employees who can deliver cost and time savings while simultaneously improving quality are irreplaceable.

Lean Management focuses on the removal of waste – any activity or by-product that is not necessary to deliver the product or service your customer values. Removing waste or mud shortens service times, increases capacity and reduces operational costs. It also improves the working environment for staff members by making work easier to perform.

At its heart, Lean is about process flow. Lean techniques optimize process:

  • Execution – Results are achieved without rework, delays, handoff failures
  • Balance – Customer value is delivered on time without excess inventory & overtime

The perfect Lean process is 100% efficient and in sync with customer needs/demand.

Lean can be implemented as a standalone solution or integrated into other process improvement methodologies (e.g. Lean Six Sigma). The Essentials of Lean Process Improvement 4-Day Boot Camp Certificate Program delivers Lean tools and concepts within a holistic framework that can be applied in any organization. Specifically, you will learn how to:

  • Map process value steams to capture flow, cycle time and failure points
  • Identify and eliminate muda (waste and non-value-added activities)
  • Use kaizen events to measure and improve processes
  • Failsafe execution with poka yoke and 5S techniques

4-Day Outline

Day 1

  • Fundamentals of Lean
    • Maximizing value and minimizing waste
  • Mapping the Value Stream
  • What does the customer value?
  • System mapping
  • Process maps
    • Value Stream Mapping
    • Process flow charts

Day 2

  • Optimizing Flow
  • The Single Piece Flow concept
  • Streamlining your process
    • Value vs. Non-Value Added
    • Waste reduction / Muda elimination
  • Reducing Cycle/Service Time
    • Capturing value producing time/cost
    • Using Takt time
    • Kanban / Pull production
    • Level loading to demand (Heijunka)

Day 3

  • Measuring & Improving Processes
  • Identifying pulse points
  • Finding root causes
    • Pareto diagram
    • Trend chart
    • Scatter diagram
    • Fishbone diagram
  • Scope of improvement
    • Histogram
    • Process S-curves

Day 4

  • Managing for Perfection
  • Monitoring metrics
  • Standardizing work
    • 5S
  • Process failsafes
  • Poka Yoke
  • FMEA
  • The Lean mentality
  • Launching Kaizen Events