Lean Manufacturing Boot Camp

Our virtual lean manufacturing bootcamp is an online version of our full programme. Delivered by expert coaches with several years of practical experience in building and sustaining continuous improvement environments, this course comprises challenging content that offers thought-provoking insight into lean thinking.

What you’ll need

  • Access to your own compatible device (the course is highly interactive and needs independent input)
  • There are no minimum academic requirements for this course

How it works

  • Live virtual classroom sessions via Zoom
  • 10 sessions delivered in 3.5-hour blocks over 10 weeks

Modules

Module One: Lean Thinking

Purpose:

To explore traditional lean thinking its origins and development and challenge the principles and perceptions that define lean.

Learning covered:

  • Development in lean thinking
  • History and origins of lean
  • Lean principles and behaviours
  • Ideal behaviours for lean implementation
  • Systems and tools for lean implementation
  • Sustainable lean implementation
  • Practical application and case studies showing a variety of approaches

Module Two: Systems Thinking

Purpose:

To explore Enterprise Excellence frameworks and models, and to understand the different approaches to sustainable excellence. We will look at how the basic concepts and principles enable excellence and how it connects with lean thinking.

Learning covered:

  • Ideal behaviours for improvement
  • Culture for excellence to thrive
  • Exploring existing models
  • EFQM
  • Deming Prize
  • Malcolm Baldridge
  • Shingo
  • WCM
  • Practical application and case studies

Session Three: Process Mapping

Purpose:

  • To understand how and when to use Process Mapping
  • To enable delegates to use Process Mapping techniques confidently in a variety of situations
  • To understand how Process Mapping differs from Value Stream Mapping

Session Four: Value Stream Mapping

Purpose:

  • To be able to identify Value Streams
  • To understand why Value Stream Mapping is so important to successful Lean implementation
  • To understand the current and future state

Session Five: Visual Management

Purpose:

To see how visual thinking accelerates and sustains continuous improvement by making it simplistic and effective, so that not only opportunities but also solutions are clear.

Learning covered:

  • Visual management systems and tools
  • Ideal behaviours for visual lean
  • Visual thinking: know, do, share model
  • Systems and tools to enable sustainable visual environments
  • Workplace organisation principles
  • 5S, layout, ergonomics
  • Visual factory principles
  • Visual controls and detection
  • One-point lessons
  • Error proofing and elimination
  • Visual measurement
  • Visual management using 5W1H
  • Creating visual standards and sustaining gains
  • Practical application and case studies

Session Six: Problem Solving 1

Purpose:

To explore various problem-solving tools and techniques, that will enable you to take identified improvements and rigorously develop solutions to these challenges. Effective problem solving is at the heart of continuous improvement, and the next two sessions will explore the difference between continuously improving and continuously problem solving.

Learning covered:

  • Ideal behaviours for improvement
  • Problem solving selection and definition
  • 5W1H
  • 5WHYS
  • Fishbone diagrams
  • Cost and likelihood analysis
  • Ease and benefit analysis
  • Swimlane cause and effect
  • Why using effective problem-solving enables continuous improvement
  • How to combine problem-solving tools as part of a systemic approach
  • Practical application and case studies

Session Seven: Problem Solving 2

Purpose:

To build further upon the learning from the previous problem-solving skills sessions by introducing a selection of complementary thinking and tools to sustain solutions and balance risk. We will explore how to measure improvement, what to measure and how to align this to measurable improvement cycles.

Learning covered:

  • Ideal behaviours for improvement
  • What to do to implement solutions using PDCA thinking and A3
  • A3 proposition, status, and charters
  • Effective measurements
  • Decision-making
  • FMEA
  • Problem-solving implementation
  • Practical application and case studies

Session Eight: Running Improvement Projects

Purpose:

To bring together the skills learned in previous sessions and explore how these combine into a system for improvement. We will be asking what is systems thinking and how will taking a systemic approach enable sustainable improvement? We will explore the key systems that every organisation should consider improving.

Learning covered:

  • Ideal behaviours for ideal performance
  • Systems and purpose enable ideal behaviours
  • What is a system?
  • What is the purpose of a system?
  • What is the purpose of your continuous system?
  • Typical lean systems and tools
  • Management/improvement/performance/people/quality systems
  • Current and future state systems mapping
  • Interdependent, interpersonal relationships within systems
  • How systems have a profound effect on behaviour
  • Effectiveness as a whole system, efficiency as focusing on single components

Session Nine: Coaching for Improvement

Purpose:

To provide you with the mindset and toolset that will enable you to implement sustainable improvement. It is essential to create an environment in your organisation which enables people to engage in daily improvement freely and willingly. During this session we will introduce techniques for coaching effective improvement.

Learning covered:

  • Ideal behaviours for coaching lean thinking
  • PDCA thinking
  • A3 thinking
  • What is coaching, and when to use it
  • What is facilitation and when to use it
  • What is mentoring, and when to use it
  • The GROW model as an approach to coaching
  • Practical application and case studies

Session Ten: Implementing Sustainable Lean Thinking

Purpose:

In this last session, all the previous learning from the bootcamp is brought together. Including, how you will apply it within your own organisation to increase individual and organisational performance, and embed a culture of sustainable improvement.

Learning covered:

  • Ideal behaviours for improvement
  • PDCA, A3
  • Improvement scope and definition
  • Starting with the end in mind. What would success look and feel like?
  • Stakeholder and communication management
  • RACI
  • TIP plans
  • Cross functional teams
  • Creating a basic project plan
  • Creating a culture and climate for sustainable improvement
  • The Ambrose Model for complex change
  • Kotter’s Eight-Step Model for Change
  • Measuring outcomes
  • Practical application and case studies

Speak to the team