Workshop on Strategy for Operational Excellence: The Lean Principle

Program Overview:

Lean is about organizational transformational towards operational excellence. If your organization strategy addresses operational and organizational excellence, this course will be of great value to you. In this course you will discover how to develop Lean Strategy, objectives and explore the world of Lean tools. Further, it will discuss how to embark on a Lean journey in your organization.

For Whom:

This program is designed for all professionals who are involved in hands-on initiatives focusing on operations excellence and improving speed, as well as those who are responsible for linking, measuring and improving the performance of the organization.

Learning Objectives:

At the end of the program, participants will be able to:

• define and explain lean concepts and its importance for organizations;
• identify typical process waste in organizations and the importance of removing such waste for organization’s profits, competitive edge, and customer satisfaction;
• recognize how lean concepts can directly address the elimination/reduction of operating costs, cycle time, and non-value-added activities;
• develop an effective lean implementation plan; and
• apply lean implementation methodologies.

Course Outline:

Day 1: Introduction to Lean Principles

• Aligning Strategy with Lean Principles
• Core Concepts
• The Benefits of Lean
• The History of Lean
• Quality Function Deployment (QFD)

Day 2: Components of Lean (1)

• Five Lean Principles
• Building Blocks of Lean
• The 8 Types of Waste – Waste Elimination Strategy
• Value Stream Mapping (VSM)
• 5 S program: Sort, Straighten, Sweep, System, Sustain
• Quick Changeover
• Single Minute Exchange of Dies (SMED)

Day 3: Components of Lean (2)

• Standard Work
• Single Piece Flow
• Cell Layout
• Total Productive Maintenance
• Point of Use Storage (POUS)
• Visual Organization
• Spaghetti Diagrams
• Poka Yoke

Day 4: Lean and Six Sigma: A One-Two Punch  

• Six Sigma at a Glance
• Key Definitions
• Understanding Process Capability
• Voice of the Customer (VOC)
• The DMAIC Process
• Areas to Consider for the Combo
• Comparison of Lean to Six Sigma-Approach

Day 5: Measurement &

Lean Implementation Road Map

• What is a Key Performance Indicator (KPI)?
• Developing your Lean KPI
• Obstacles to Measurement
• Maintaining a Business Focus through

Measurements

• Implementation Road-Map
• Selecting Lean Projects
• Barriers to Success and Employee Involvement
• Leading Improvement Teams and Handling Change

Training Methodology

Lectures, discussions, exercises, case studies, audio-visual aids will be used to reinforce these teaching/learning methods.