+1-925-975-0500

Pivotal Resources - Continuous Improvement

 

Lean Training Agenda

The following is a typical Lean training agenda. Pivotal Resources can customize the course material to client training requirements, as well as certification objectives.

Simply click on the subject content below to see more information, and click on the content again to close the box.

The Value Of Lean Enterprise
  • Key concepts and strategies overview
  • Concepts/Tools
    ACTIVITY: Work through the Can Manufacturing case example (from “Lean Thinking”) and perform manual calculation of “manufacturing cost” and “total system cost” for two different supply chain management options
Lean Initiative: Define
  • Set-up
  • Vision
    ACTIVITY: Draw and compare a “to-be” ideal process with the current state. Describe the “perfect” process (20 min)
  • The Lean initiative charter
    ACTIVITY: Write opportunity and goal statements for an initiative, and determine what additional facts or measures will be needed to quantify and validate the same (20 min)
  • Documenting the process & requirements
    ACTIVITY: Define a SIPOC and identify customer requirements for the key output (50 min)
  • Planning to drive change
    ACTIVITY: Identify stakeholders and note their requirements on the SIPOC (20 min)
Lean Initiative: Investigate
  • Identify obvious root causes of waste and variation
  • Value and Time Analysis
    • Process Mapping builds to Value Stream Mapping
    • Value Stream Mapping – why, what, and how Components
      ACTIVITY: Each team creates a Value Stream Map from one or more of the SIPOC elements for their process (60 min)
      FOLLOW-UP ACTIVITY: Estimate or collect actual data on cycle time and inventory within the process to place detail on the maps (90 min)
      ACTIVITY: For the VSM mapped before, identify VA, VE and NVA steps (20 min)
      ACTIVITY: Calculate and place WIP / Inventory information on the VSM (20 min)
      ACTIVITY: Observe / estimate wait and work time for each step in the process. Place information on the map (30 min)
      ACTIVITY: Identify and mark on the map ¬ communication flow, ¿pullî and pushî flows, scheduling functions (20 min)
  • Assess value stream for opportunities to enable future flow solutions
    ACTIVITY: Identify issues / concerns with the process and customer impact. (30 min)
  • Investigating causes
    ACTIVITY: Use a fishbone diagram to determine the causes and determine 1-3 most likely causes for further investigation (40 min)
  • Confirming with data
  • Investigating causes
    ACTIVITY: Identify (on the VSM) the yield of each process step, get RTY (45 min)
Lean Initiative Attainment: Streamline
  • Identifying Solutions for Just in Time Flow and Pull
    • Red tag process
      INDIVIDUAL ACTIVITY: Tag unnecessary items in the work area and ¿claimî others° marked items if needed (30 min)
    • Generating new innovative ideas through brainstorming, multi-voting and other techniques
      ACTIVITY: Using the tools learnt, identify 5 ¬10 solution ideas, and determine steps to make final choice (45 min)
      ACTIVITY: Based on solutions identified, modify the value stream map (45 min)
  • Advanced “flow” solutions
  • New tools and “mindset” required for establishing JIT flow
    • QuickChange (a.k.a. SMED)
      ACTIVITY: Identify potential flow solutions and discuss the costs/risks associated with changes, their impact, mitigating strategies (60 min)
    • Cell Design
      ACTIVITY: In sub-teams. visit critical work cell, and re-align work to optimize design for sub-processes (60 min)
    • Scheduling level production and leveling demand
      ACTIVITY: Brainstorm to develop further advanced flow solutions and reduce list, using tools learned earlier to select best solutions (45 min)
  • Selecting final solutions
    ACTIVITY: Using the Impact /Effort matrix created earlier, review each potential solution for an iterative solution selection process (60 min)
  • Implementing solutions
    ACTIVITY: Develop a preliminary action plan based on the solutions decided upon earlier. (45 min)
Lean Initiative Control
  • Controlling the flow using “Pull” (including Kanban), plus planned “report-outs” from teams to Champions / Sponsors
    ACTIVITY: Review sources of information about customers, identify best sources, and plan “action” to obtain/communicate demand information to all process participants (20 min)
    ACTIVITY: Identify loops in the process, optimum methods to control production/delivery and target sizes for an action plan for a Supermarket (60 min)
  • Advanced lean tools to control Just-in-Time production or service delivery with ongoing measurement.
    • Monitoring and control by documentation, dashboards, control charts
      ACTIVITY: Identify measures for ongoing monitoring, who needs these, formats for measures, data collection / presentation (60 min)
  • Visual Control
    ACTIVITY: Using the chart provided identify measure components and develop an action plan for performance accountabilities (45 min)
  • Documentation and translation
    ACTIVITY: Identify “spin-off” projects to pass of to champion / leadership team (15 min)
    ACTIVITY: For the project discussed, review progress, firm up action plan for close within 30–60 days (30 min)

Contact us for more information.