Lean Methods Accelerator

Templates

Course Map

Total Estimated Hours:  18

SESSION 1: Introduction to Lean Methods 1.85 HOURS

  • Introduction
  • Introduction to Lean Six Sigma
  • The Cost of Poor Quality
  • The Lean Blueprint
  • Input Determines Output
  • DMAIC Improvement Process
  • Thought Process Maps
  • Session Wrap-Up and Skill Check

SESSION 2: Lean Tools to Define and Measure 6.3 HOURS

  • Introduction
  • Introduction to Process Mapping
  • The Source of Value
  • Gemba Walks
  • The 3 M's and 8 Wastes
  • Types of Process Maps
  • Value-Added Flow Charts
  • Spaghetti Diagrams
  • Process Metrics
  • Takt Time
  • Value Stream Mapping Toolset
  • Line Balancing (Heijunka)
  • Measurement and Data Types
  • Discrete vs. Continuous Measurements
  • Pareto Chart Toolset
  • Benchmarking
  • Kaizen Toolset
  • Session Wrap-Up and Skill Check

SESSION 3: Lean Tools To Analyze, Improve, and Control 11 HOURS

  • Introduction
  • A3 Problem Solving
  • 5-Why, 1-How Analysis
  • Design for Six Sigma
  • Design For Lean - Supply Chain Dynamics
  • Error-proofing
  • Continuous Flow Toolset
  • Quick Changeover Toolset
  • Cellular Processing Toolset
  • The Theory of Constraints (TOC) Toolset
  • Introduction to Pull Systems
  • Types of Pull Systems
  • Core Process Pull Systems (WIP Cap) Toolset
  • Pull Scheduling
  • Visual Management
  • 5-S Approach
  • Introduction to Total Productive Maintenance (TPM)
  • TPM Objectives and Benefits
  • TPM Metrics
  • TPM Maintenance Activities
  • Standard Work
  • Leader Standard Work Toolset
  • Session Wrap-Up and Skill Check
  • Course Completion and Feedback
  • The Lean Journey