Lean Processes and Tools

This course provides delegates with a practical introduction to the lean methods and tools so that they can undertake simpler improvement activities.

Lean thinking is based on the legendary Toyota Production System that produces very high quality products; in a very short time and at a low cost. To many people and organisations, achieving all three of these goals simultaneously is an impossibility. Lean provides a methodology and tools that enable organisations to make significant improvements in lead time, cost reduction and product or service quality.

This two day course uses a blend of theory and practical exercises. During the course delegates will develop an understanding of:

• The key elements of the Lean thinking and methodology
• Voice of the customer; customer value and the value stream
• The identification (learning to see) and elimination of waste in processes
• The main lean tools and techniques and their practical application

Prerequisites

• Delegates should have completed the one day Lean Awareness course

Outline

• Lean Project Charter
• Voice of the customer and customer value
• Process flow diagrams
• Value stream mapping-current state
• Lean measurement
• Analysing variability
• Operational definitions
• Data collection
• Analyse current state
• Determining lean metrics
• Identifying waste (learning to see)
• Root cause analysis tools
• 5S, mistake proofing and visibility principles
• Push versus pull and kanbans
• Set-up reduction, SMED
• Standard work
• Workload balance and takt time
• Future state value stream map
• Measuring and sustaining the gain
• Ownership reward and recognition

Certification

Completion of all elements of the Lean Programme will enable delegates to attend the Lean Six Sigma Practitioner course and, having completed the exam and a suitable project, become a certified Lean Six Sigma Green belt.