Lean Process And Six Sigma Training

Duration: 2 days

Introduction

To survive in this globally competitive market, companies cannot rely on “doing the same thing over and over again and expecting a different result” (Einstein). To gain competitive advantage, companies have to operate with little “fat” – i.e., “lean”. Lean” means doing more with less; working smarter rather than harder; improving quality and doing things right the first time; eliminating waste and improving efficiencies.

The Challenge:

Often, the thought of completing a RIE (Rapid Improvement Initiative) or project would cause an employee great distress. The thought of “project managing” sounds daunting and in their minds, should be left to the PM’s! Lean Six Sigma is a simple 5 step process that’s user friendly and easily applied by all levels of staff. This workshop will give participants an overview of the Six Sigma methodology, and some of the tools required to deploy Six Sigma in their own organizations.

Upon Completion of the Course, delegates will:

• Have a good high-level understanding of Lean Six Sigma methods (DMAIC) and prepare them to participate, as contributors, to Lean Six Sigma projects
• Understand how to perform and interpret Six Sigma tools and how to use standard principles of Lean
• Understand the activities, deliverables and key concepts of Team problem solving
• Be able to identify potential improvement opportunities in their organization and provide Subject Matter Expertise to support Green and Black Belts.

“Once you understand and better document business processes, you’ll start to slice out areas of improvement and realize financial savings.”

Course Outline

Module One: Getting Started

• Icebreaker
• Housekeeping Items
• The Parking Lot
• Workshop Objectives

Module Two: Understanding Lean

• About Six Sigma
• About Lean
• History behind Lean
• Toyota Production Systems
• The Toyota Precepts

Module Three: Liker’s Toyota Way

• Philosophy
• Process
• People and Partners
• Problem Solving

Module Four: The TPS House

• The Goals of TPS
• The First Pillar: Just In Time (JIT)
• The Second Pillar: Jidoka (Error-Free Production)
• Kaizen (Continuous improvement)
• The Foundation of the House

Module Five: The Five Principles of Lean Business

• Value
• Value Stream
• Flow
• Pull
• Seek Perfection

Module Six: The First Improvement Concept (Value)

• Basic Characteristics
• Satisfiers
• Delighters
• Applying the Kano Model

Module Seven: The Second Improvement Concept (Waste)

• Muda
• Mura
• Muri
• The New Wastes

Module Eight: The Third Improvement Concept (Variation)

• Common Cause
• Special Cause
• Tampering
• Structural

Module Nine: The Fourth Improvement Concept (Complexity)

• What is complexity?
• What causes complexity?
• How to Simplify?

Module Ten: The Fifth Improvement Concept (Continuous improvement)

• The PDSA Cycle (Plan, Do, Study, Act)
• The DMAIC Method

Module Eleven: The Improvement Toolkit

• Gemba
• Genchi Genbutsu
• Womack’s Principle
• Kaizen
• A Roadmap for implementation

Learners are presented with real life industry specific case studies. With the acquired knowledge and confidence, delegates can take their enhanced skills back into the business environment and apply them successfully.

A comfortable climate is created by the group facilitator, thus enabling delegates the opportunity to introspect and evaluate themselves: their skills; generate ideas and solutions to problems; and plan suitable growth in the workplace.

Delivery Method: (Internal or External)

2 day, instructor led, classroom-based training sessions (08.30 to 16:30)

All our courses are outcomes based and facilitated to encourage active delegate participation using:

• Break-away sessions
• Relevant business exercises
• Role-plays / simulations
• Questionnaires / checklists
• Discussion activities and
• Case studies

All delegates will receive:

• Manuals, workbooks/files
• Tea, lunches and all refreshments (external courses)
• Certificate of Attendance