LEAN TRAINING

Our approach is based on having the participants come to the training sessions with pre-approved Lean and projects (or at least with projects in mind), ideally with some process data already available for analysis. The sessions would focus on these projects throughout the training so that exercises and workshops are based on real-life issues for maximum impact and learning. By using this approach, savings from projects usually result in a return on training investment of between 5 and 100 times of initial cost.

Lean White Belt Session Outline (Can be half-day or 1-day session)

-What is Lean?  What is Six Sigma?
-How Lean and Six sigma can improve any process 
-Value-Added (VA) and Non Value-Added (NVA) activities 
-Recognizing NVA/waste through ‘8 wastes analysis’ and waste walks 
-Tools to see and understand the process and identify waste (7 Basic tools)
-Value stream mapping and process mapping
-Just in Time, Balance, Flow and Pull 
-The benefits of an improved ‘Leaned’ process 
-5S and the Visual Workplace 
-Kaizen/Rapid Improvement events 
-Error-proofing 
-Work cell design
-Sustaining improvement through Standard Work and effective Control Plans 
-Lean/ Six Sigma structure and roles 
-Your expectation and likely involvement with Lean / Six Sigma in the future

Lean Yellow Belt Course Outline (3 days)

-Explain the fundamental concepts and principles of Lean Enterprise 
-Introduction to lean concepts, tools (7) and techniques
-Value-added and non value-added activities
-How Lean concentrates on waste identification and reduction
-Understanding the Voice of the Customer (VOC) and Voice of the Process (VOP)
-Rationale and benefits of implementing a Lean approach
-The eight sources of waste (Muda) plus Mura (Unevenness) and Muri (Overburden)
-Effective problem statements using the 5W2H approach
-Construct SIPOC, Process Flow and Spaghetti Maps
-Construct current and future state Value Stream maps and deeper-dive process maps
-The use of A3 problem-solving methodology
-Value Added Assessment and ‘the Hidden Factory’
-Pareto Charts/Analysis 
-Data collection strategies
-Effective Operational Definitions
-Lean Metrics and Capability Analysis
-Create Cause & Effect diagrams and drill down to root cause using ‘5 Whys’ approach
-Understand how to plan and participate in Kaizen improvement events
-Batch Reduction, Kanban, Leveling and Improving Flow 
-Workplace organization including 5S, visual workplace & standard work
-Create effective ongoing controls for sustaining improvements

Lean Green Belt Training (Additional 2 days for Lean Yellow Belts with the following topics – Total 5 days:)

-The people side of Lean and project management
-The importance of Change Management, Leadership and Culture
-Project Identification, prioritization, and completion – Kanban Boards, Impact/Effort Analysis
-Project Charters and A3 Methodology 
-Identifying Waste and improvement opportunities (‘8 Wastes’ and Gemba/Waste Walks) 
-Error Proofing 
-Prioritizing and planning improvement activities (Impact/Effort analysis)
-Planning and Executing Kaizen Events 
-Implementing and tracking performance improvements
-Quick Changeover Techniques
-Total Productive Maintenance 
-Work cell Design 
-Ongoing Control Methods for Sustainment (Control charts, Reports, Audits, etc.)
-Implementing Daily Management, Standard Work, Layered Audits and Leader Standard Work

Lean Black Belt (Additional 5 days for Lean Green Belts with the following topics – Total of 10 days)

-Hoshin Planning
-Theory of Constraints
-Deployment Planning and Implementation:
-Daily Management, Standard Work, Leader Standard Work, Metrics and Visual Management
-Leading and Managing Projects
-Advanced Lean Topics: Theory of Constraints, Error-Proofing, Mapping Approaches, Time Studies, Work Cells
-Train-the-Trainer, Coaching and Training, Planning and Leading 5S and Kaizen events
-Leadership and Champion roles and responsibilities
-Facilitating and Leading Teams