Lean Foundations (one-day course)

Participants will understand the principles of Lean and be able to apply these powerful concepts in their workplaces immediately following the class.

These courses can be delivered as stand-alone seminars or within a series.

LEAN FUNDAMENTALS

Understand what Lean is and be able to define the value stream and standard work, recite the seven wastes and begin to identify them in processes, and contrast value-added vs. non-value- added activity.

LEAN LEADERSHIP

Contrast Lean vs. traditional management, understand and apply The Five Whys tool, describe the Plan-Do-Check- Act Cycle (PDCA), and understand management concepts that create an effective Lean organization.

WORKPLACE ORGANIZATION

Define, implement and monitor results of 5S, point of use and visual controls, explain how applying the concepts can eliminate waste in the workplace, and develop ways to standardize and sustain improvements.

CONTINUOUS FLOW

Define and calculate takt time, cycle time, and lead time and understand how they are applied in a Lean organization. Know the difference between flow and batch, why we strive for one piece flow, and how flow is established in an organization. This course includes the popular interactive “Penny Pot Industries” simulation.

Lean Management Training

The following courses can be delivered as stand-alone seminars or within a series that gives practitioners powerful tools to effectively deploy Lean throughout their organizations.

LEAN FOUNDATIONS

Learn the fundamental concepts of the Toyota Production System (TPS) including: value/non-value, the value stream, seven wastes, and more.

STANDARD WORK

Understand the importance of standard work, what it is, why Toyota considers it to be one of the foundations of their operating system, and why many companies fail to execute sustained lean initiatives.

LEAN MANAGEMENT

Contrast lean management vs. traditional management – business philosophy and problem solving, understand and apply The Five Whys tool, describe the Plan-Do- Check-Act cycle (PDCA).

THE LEADER’S ROLE IN LEAN TRANSFORMATION

Contrast leaders vs. managers, expectations of leaders, mentoring and coaching, barriers to change.

5-S AND POINT OF USE

Learn an important tool for removing excess materials and/or tools from the workplace and organizing the required items (using visual controls) so they are easy to find, use and maintain. 5-S helps create a self-sustaining culture, which promotes a neat, clean, efficient, and safe workplace.

VISUAL CONTROLS

What they are, types, applications, how they support standard work, and make it easy for people to “do the right thing.”

TAKT TIME, CYCLE TIME, LEAD TIME

Understand the differences between takt time, cycle time, and lead time; how to calculate them, how cycle time relates to takt time, and the goal of continuous improvement.

DOCUMENTING REALITY

Gain hands-on experience documenting the current state of a process using stopwatches, time observation forms, spaghetti diagrams, sticky notes and more. Documenting the current state is critical to understanding what is actually happening in the process, not what is supposed to happen. Metrics are established, important data are captured, and these become the baseline for improvement objectives.

CONTINUOUS FLOW

Review takt time, cycle time, and lead time and understand how they are applied in a Lean organization. Know the difference between flow and batch, why we strive for one piece flow, and how flow is established in an organization. This course includes the popular interactive “Penny Pot Industries” simulation.

PERCENT LOAD CHART

Understand the relationship of cycle time to takt time, learn how to assess and correct imbalances in processes, stabilize and level production through such processes using the percent load chart and other tools.

PROCESS ANALYSIS

The tools learned in earlier sections are brought to bear in analyzing, understanding, and correcting imbalances in processes. Understand how machine capacity, operator loading, process variation, and more are important factors in why production usually occurs at a pace other than takt time.

MISTAKE PROOFING

Learn the discipline of making it easy for workers to do the right thing, errors vs. defects – why they occur and how to address them, and review various types of mistake proofing devices.

SETUP REDUCTION

Understand how reducing setup time impacts flow and why many companies batch process rather than reduce setup time. Contrast internal vs. external setup, and learn how to perform setup reduction activities.

TOTAL PRODUCTIVE MAINTENANCE

Learn why TPM is critical to the Lean enterprise, understand the difference between TPM and traditional maintenance programs, and that TPM is a Lean improvement process rather than a maintenance program that promotes teamwork between leaders, operators, office staff, and maintenance personnel.

RUNNING A KAIZEN EVENT

Learn how to properly plan and execute continuous improvement (kaizen) events, conduct pre-work, set event scope, objectives and metrics, prepare yourself and others to participate, facilitate an event and report-out following an event.

BIAS FOR ACTION

A fast-paced module designed to encourage leadership and staff that it is better to try and fail than not try at all. Leaders must lead by supporting improvement efforts – including unsuccessful ones – if done for the right reason, avoiding the “analysis paralysis” trap.

PROCESS MAPPING

Learn how a process map can be an effective visual tool in your arsenal for exposing waste in processes. It is often used for business processes where time observations are difficult to capture and where many hand-offs in information, signatures or approvals occur. Process maps are excellent tools for helping participants understand each others tasks and the impacts each has in the overall process.


If you are interested in Lean Training and would like to schedule a consultation, contact us at 503-250-2235 or email us at info@petersco.net.