Lean Manufacturing Boot Camp

Course Schedule

Module 1 | Lean Thinking

History, background and the guiding principles of lean manufacturing concepts including customer driven value, elimination of waste and continuous improvement culture. Understanding how companies become lean and how you adopt a Lean mindset to drive change in your own business. Understanding the relationship between culture and continuous improvement and how to act on the quick wins.

Module 2 | Visual Management

Understanding the interactions 5S has on a Lean organisation and how it enables Flow (and standardisation) to be achieved. Calculation and benefits of applying Overall Equipment Effectiveness (OEE), the mechanics of Total Productive Maintenance (TPM) and recognising the need and when to apply it. Understanding process of changeover analysis and methods of reducing unnecessary/excessive downtime.

Module 3 | Process Mapping

Popular types of Process Mapping techniques that capture cause and effect and Right First Time (RFT) methodology and tools from Fishbone to Pareto. Creating a process map, and how mapping linear sequences of the activities that make up a business process, helps to identify bottlenecks or unnecessary steps in current processes and eliminates waste. How Process Mapping differs from Value Stream Mapping (VSM). Introducing Kaizen workshops, your daily Kaizen and blitz events, guidelines for success, teamwork and how to sustain continuous improvement gains.

Module 4 | Value Stream Mapping

Identifying your value streams, and why VSM is so important to Lean implementation. The 7-Wastes and key drivers for ‘un-lean’ behaviour. Developing a Lean Future State by optimising labour, lead-times and inventory, linking improvements to financial benefits and how culture and behaviours can impact on a lean deployment programme.

Module 5 | Systems Thinking

Development of a systematic approach to the elimination of waste and none-value added activities, an entire business approach. What Lean system is right for you? Results and behaviours and understanding variation. Human centred design and knowledge, and systems integration.

Module 6 | Problem Solving

To understand why problem solving is a vital element of any Lean implementation, how to approach organisational problems characterised by continuous improvement methodologies. Introduction to Root Cause Analysis and Statistical Process Control (SPC) to aid time management and the achievement of measurable results.

Module 7 | Problem Solving Tools

To appreciate what is meant by Lean principle 5 – Perfection. Develop an understanding of the tools and techniques required for quality management, and how detailed insight and analysis supports your continuous improvement strategy. Recognise how the use of quality tools can be applied to resolve specific problems in support of lean developments – including the PDCA problem solving cycle and the Five Whys.

Module 8 | Coaching for Improvement

To identify and appreciate the qualities and attributes required of a Lean leader, how to compare and contrast ‘Traditional’ management styles and leadership behaviours that foster cultural change. How to facilitate CI activities, understanding the difference between coaching and mentoring, and how to coach people to achieve improved CI results. Developing the communication skills that enable respectful and progressive CI strategies including models and frameworks for planning.

Module 9 | Lean Implementation

How to on-board your Lean mindset, establishing and maintaining routine to ensure sustainable change. A3 thinking, problem solving and statements. Why map? Insightful implementation, visualisation using graphs and flowcharts – what works for you. FMEA, failure model effects analysis and pitfalls of performance management. Future state and current state. Measuring success – What good looks like.

Module 10 | Operational Excellence

The value and purpose of having a well thought through and communicated lean philosophy, and the impact of a lean implementation strategy on operational excellence. The value of Human Systems, the need to engage with our teams and the critical factors necessary for effective and sustainable Continuous Improvement and the transition to Operational Excellence. Reflection and discussion on the processes and systems necessary to align the “top-to-bottom” resources in your organisation, get buy-in to achieve corporate aims and objectives.

Delivered by highly experienced practitioners in Lean, Six Sigma and manufacturing leadership, all modules include case studies, exercises and reflective discussion.

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