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Training - Lean Master Class

Lean Master Class Course Details

"A very enjoyable, informative week and an excellent delivery of information!"

"Gave me a deeper level understanding of Lean and how to deploy it!"

Gives an in depth understanding of Lean fundamentals, classic and advanced Lean tools and guidance on Lean deployment, enabling participants to successfully lead Lean deployments within their organisations, leading to significant business improvements. Practical applications of Lean will be introduced along with hands-on exercises, tutorials and a case study to ensure rapid learning and knowledge retention.

Target Group

Lean Leaders, Improvement specialists, Managers and Lean practitioners wishing to advance their knowledge.

Those involved in process excellence initiatives within trasactional or manufacturing environments.

Prerequisites

Ideal candidates possess good communicational skills and enjoy working in teams. Candidates should be results oriented and enjoy making improvements and accelerating change in their work environment.

Course Agenda

During the 5 days of training are spread out over four months, you will cover the following topics.

Introduction & Fundamental Lean Principles

Course Introduction	Course admin, aims, objectives and outcomes, course roadmap
Introduction to Lean	Why Lean (profit=price-cost, World Class), What is Lean – History, TPS model Example results achieved – Toyota, Danaher, others
Basic Lean Concepts	Lean vs Six Sigma, Culture, PDCA, Lean principles
The Lean Way	The Toyota Way, Lean Philosophy, Leadership
Specifying Value	Muda (7 wastes), Mura (variation), Muri (overburden), office wastes, service wastes
Value Stream Mapping	VSM CSM (demand, processes, Info, lead-time, process time)

Lean Foundations

Direction Management (Hoshin Kanri)	Benchmarking, Mind Of Customer, competitive forces, X-matrix, QFD, catchball
Breakthrough Improvement (Kaikaku)	3P, DfSS, breakthrough projects, Six Sigma, Kaizen x10k
Continuous Improvement (Kaizen)	Basic principles, PDCA/DMAIC, Kaizen blitz, daily Kaizen, suggestion schemes, A3 reporting
A3 Thinking	A3 report
Standard Work	Concept, elements of SW, SW for all (prod, admin, maint, leader SW), visual, 5S, implementation

Flow

Load Levelling (Heijunka)	Demand amplification, queuing theory, Mura & Muri, Yamazumi charts, levelling methods (runners/repeaters, strangers +), mass customisation
SMED	Batch vs flow, examples of batching, set-up: observation, improvement, control
TPM	Reactive, autonomous, preventative, predictive, OEE, implementing TPM
JIT	Flow, dedicated lines, Takt, flow in the office, flow in service, practical issues
Pull (Kanban)	Pull, Kanban signals, sizing the Kanban, economic order quantity, implementing a Kanban

Man/Machine & Problem Solving Tools

Autonomation (Jidoka)	Definition, 10 steps, machine cells, monument m/c’s, 3D, application to admin and service
Error Proofing (Poka Yoke)	Source, self, successive, examples, office, service
Problem Solving Tools	5W2H, brainstorm, affinity, CEDAC, Pareto, 5Whys
Graphical Analysis	Time series, column/bar, pie, bubble, radar

Implementing and Managing Lean

Implementing Lean	Deployment process, examples of Lean deployment
Developing a Lean Culture	Lean culture, 14 management principles, change management
Facilitation Skills	Facilitating a workshop – charter, team selection, preparation, leadership/coach, report-outs
Daily Management	Gemba focus, Hr by Hr management, balanced score cards/True North & cascade of KPIs, QOS
Course Close	Continuing your Lean journey, close of course

Location and Duration

Our courses are held in Birmingham, London, Leeds and Newcastle Upon Tyne (view our course calendar). All of our courses include full documentation in hard and soft copy (PDF files). Lunch is provided and the course consists of one full day training.

Why Book a Six Sigma Yellow Belt SigmaPro course?

Here is what we offer...	SigmaPro
Over 20 years experience
All trainers are Certified Lean Six Sigma practitioners
Proprietary course material, developed by experienced Lean Six Sigma practitioners
An introduction to the DMAIC & DMADV methodologies
Mixed class curriculum (lecture, workshops, exercises, group work, etc.)
Personal, competent and free advice at any stage of the educational process