Lean 1+2+3: Lean Fundamentals Problem Solving and Advanced Tools

Course Map

Total Estimated Hours:  22

SESSION 1: Lean Fundamentals 4.05 HOURS

  • Introduction
  • Learning and Problem Solving with AI
  • The 5 Lean Principles
  • DMAIC - The Improvement Process
  • Process Thinking
  • The Source of Value
  • The Source of Value: Gemba
  • The 8 Forms of Waste
  • Process Mapping Overview
  • Value-Added Flow Charts
  • Takt Time
  • Spaghetti Charts
  • 5-Why, 1-How
  • 5-S Approach
  • Visual Management
  • Standardized Work - Overview
  • Session Wrap-Up and Skill Check

SESSION 2: Problem Solving 8.65 HOURS

  • Lean 2 Introduction
  • Introduction to EngineRoom®
  • Stakeholder Analysis - RACI Matrix
  • Affinity Diagram Toolset
  • CTQC Tree Diagram Toolset
  • Operational Definition Toolset
  • Value Stream Mapping Toolset
  • Leveling Production (Heijunka)
  • Measurements
  • Discrete vs. Continuous Measurements
  • Pareto Chart Toolset
  • FMEA Toolset
  • Error-proofing
  • The A3 One-Page Report
  • Continuous Flow Toolset
  • Cellular Processing Toolset
  • Core Process Pull Toolset
  • Session Wrap-Up and Skill Check

SESSION 3: Advanced Tools 9.95 HOURS

  • Lean 3 Introduction
  • Voice Of The Customer As Specifications
  • Cause & Effect Matrix Toolset
  • Histogram Toolset
  • Trend Chart Toolset
  • Derivative Performance Metrics - Throughput Yield
  • Derivative Performance Metrics - Rolled Throughput Yield
  • Quick Changeover Toolset
  • The Theory of Constraints Toolset
  • Pull System Overview
  • Pull Scheduling
  • Replenishment Pull Overview
  • Visual Management
  • Total Productive Maintenance
  • TPM Objectives & Benefits
  • TPM Metrics
  • TPM Core Elements
  • TPM Maintenance Activities
  • Leader Standard Work Toolset
  • Session Wrap-Up and Skill Check
  • Course Completion and Feedback