Lean Thinking Process Improvement Training (Face to Face training workshop or Virtual Online workshop)

Doing Business Better offers:

  • One day face to face Lean Thinking training

  • 3 virtual online training sessions in Lean Thinking training (each session is 2 hours duration).

One-Day Lean Thinking Process Improvement Training 

This one day workshop provides participants with training, practical, interactive hands-on activities and discussions, case studies, photographic and video examples in Lean Thinking principles, tools and techniques. Participants will learn how to apply Lean Thinking process improvement and streamlining tools to improve customer experience, improve everyday work processes, to save time, effort, simplify the way they work and reduce the frustration of lengthy and often overly complicated manually handled end-to-end business processes.

In the first session, participants will learn the language of Lean and how to see wasted time and effort and other forms of non value adding activity in daily work processes. This program introduces participants to the Value Stream Mapping improvement technique. Value Stream Mapping is a highly effective business improvement tool which can be immediately applied in your workplace and lead to better outcomes for the client/customer, workforce and organisation.

This interactive program will provide participants with the opportunity to apply their new learning to current workplace processes. In the second session, participants will also take a hands-on role and begin to process map one of their key business processes in the workshop at a high level and again in detailed process steps. Hands-on practical training is the most effective method of learning and retaining knowledge. Following activities to learn how to see waste, participants being to process map an existing current processes and immediately commence identifying new opportunities for process and productivity improvement.

In the third session of the day, participants will also be made aware of a number of analytical tools to assist the process flow, eliminate variation and defects resulting in lead time reduction, improved quality and customer experience including:

  • SIPOC (Supplier Input, Process, Output, Customer)

·       5 Why’s

·       Fish bone problem solving

·       Voice of the Customer

·       Single piece flow

·       Batching

·       First In First Out (FIFO)

·       Checklists

·       Queuing theory

·       Pull and Push systems

·       Failure Mode Effect Analysis (FMEA)

·       Error proofing

·       Fix and go

·       Fast Track Fall Out

·       Ohno circle

·       Walk the Gemba

·       Tool box meetings

·       Swim Lane diagrams

·       Spaghetti diagrams

·       Kanban

·       2 bin systems

·       Takt time

·       Cellular work

·       Production levelling

·       Standard Work

·       Standard Operating Procedures

In the final session, participants learn the fundamental of process redesign and how to plan for implementation. Participants examine techniques to overcome the issues often faced by staff during Lean process review projects, which makes execution of implementation a challenge.

Program content

This program will include: 

    • Understanding the role of leadership to drive and support a culture of continuous improvement

    • How to engage staff in improving the way they work

    • Measure for Improvement and the PDSA cycle (Plan, Do, Study, Act)

    • Process improvement and measurement simulation

    • How to see the eight forms of wasted time and effort in business processes (including activity)

    • Identification of value adding and non value adding activity

    • Process Improvement Prioritisation

    • High level Value Stream Mapping

    • Detailed Value Stream Mapping activity

    • A number of analytical tools to improve productivity and process flow including Single Piece Flow, Pull Systems, Kanban, FIFO, Spaghetti diagrams, production leveling and visual controls

    • Problem Solving tools including 5 Why’s and Cause and Effect

    • Implementation planning

    • Designing an improved future state process

    • Drafting of Action Plan going forward

Learning objectives

During this program, participants will increase their knowledge of:

  • Lean Thinking principles

  • Learning to see the eight forms of process wasted time and effort

  • Identify non-value add processes to eliminate wasted time and effort

  • The Value Stream Mapping improvement techniques

  • How to use Process problem solving techniques to engage staff and make work easier to perform

  • Understanding of the Lean language

  • Understanding how to use Toll Gate reviews

  • The importance of implementation planning

  • Creating the environment for successful implementation

  • Techniques to make work processes simpler, easier to perform, faster with less errors, and with no rework and chasing for information and materials

  • Tools and techniques that can immediately be applied in your workplace to streamline processes, eliminate double handling, bottlenecks and wasted time and effort

  • How to prioritise processes for improvement and apply Lean Thinking to Departmental processes and practices

Each participant will receive an electronic set of resource templates and a workbook which they can use as a reference guide.

The program is for groups of 5 to 15 participants.  Training can be delivered on your business site or remotely via Microsoft Teams and Zoom.

Program Duration: One day 9am – 5pm

Agenda

The agenda for the one day training workshop is detailed below:

Introduction to Lean Thinking

9.00am – 10.30am

  • The origins of Lean (Not pass on a defect)

  • Lean Thinking principles

  • Learn to See Wasted Time and Effort (TIMWOODS) – Waste Walk exercise

  • The Model for Improvement

10.30am – 10.45am    Morning tea break

  • PDSA cycle (Plan, Do, Study, Act) – process improvement simulation exercise

  • Developing an idea into an improvement project

  • Process improvement prioritisation

  • Introduction to Value Stream Mapping

12.30pm – 1.00pm                 Lunch

  • High level Value Stream Mapping and activity

  • Detailed Mapping of the Value Stream of a process and activity

3.00pm -3.15pm                     Afternoon tea break

  • Problem Solving techniques

  • Process improvement idea generation

  • Applying analytical tools and techniques to your process

  • Designing an improved future state process

  • Implementation Planning

  • Coaching your team

  • Drafting an Action Plan

Workshop Duration: One day 9am – 5pm for face to face training or 3 sets of hour hour virtual online training workshops.

For more information or to make a booking contact us today.