| Module Title |
Module Content |
Business Benefits |
Duration |
|
Leading a Lean Programme
|
- Lean concepts and principles
- Benefits of Lean
- Leadership roles
- Overview of key techniques
- Lean programme organisation
- Implementation steps
- Leadership styles and change management
|
- Apply techniques in the right sequence
- Avoid initiative overload
- Focus effort to best effect
- Improve overall business performance
- Build a Lean culture
|
1 day
|
|
Lean Concepts and Principles
|
- Value and the Value Stream
- Flow and pull systems
- Perfection as the benchmark
- Cellular operations
- Kaizen and team-based improvement
|
- Increase productivity
- Reduce inventory
- Improve quality
- Reduce lead times
- Improve on-time delivery
|
3 days
|
|
Value Stream Mapping
|
- Value and the Value Stream
- Mapping techniques
- Identifying value-adding steps
- Prioritising improvement opportunities
- Organising a mapping project
|
- Visualise how value is created
- Identify non value-adding activities, delays and waste
- Highlight improvement opportunities
- Prioritise high-value improvements
|
2 days
|
|
Cellular Operations
|
- Cell concepts and principles
- Flow, layout and balancing
- Flexibility - the agile cell
- Material supply and handling
- Planning, measurement and control
|
- Cut lead times and inventory
- Increase productivity and flexibility
- Engage the shop floor work force
- Improve health, safety and job satisfaction
|
1 day
|
|
Kanban and Pull Systems
|
- Kanban and other pull techniques
- Usage pattern analysis
- Trigger levels and transfer quantities
- Pull systems for high-variety products
- Pull systems and ERP
|
- Understand where to use pull systems
- Make the right choice of pull techniques
- Stabilise flows, cut lead times, cut inventory and improve productivity
- Eliminate wasteful administration
|
1 day
|
|
Changeover Reduction (SMED)
|
- SMED techniques
- Internal & external set-up
- Set-up analysis techniques
- Principles of lean manufacturing
- Toyota production system
- Basic concepts
- Factors affecting changeover
|
- Increase capacity & productivity without buying more equipment
- Be more flexible and agile with shorter lead times
- Understand the impact on cost and waste reduction
- How to apply the techniques yourself
|
2 days
|
|
Problem Solving
|
- Problem solving framework
- Problem identification and analysis
- Root cause analysis techniques
- Brain storming and other creative techniques
- Developing solutions
|
- Identify and understand problems more clearly
- Deal effectively with problems in unfamiliar areas
- Solve problems faster
- Generate better solutions
|
1 day
|
|
5S
|
- 5S - a foundation for quality and improvement
- What the 5Ss mean
- 5S techniques
- Planning and running a 5S programme
|
- Eliminate waste
- Build pride in the workplace
- Improve plant maintenance
- Improve safety, quality and productivity
- Support continuous improvement
|
1 day
|
|
Quality Improvement Techniques
|
- The role of quality in Lean
- Process charting
- Analysing non-conformances
- Root cause analysis
- Mistake proofing
|
- Improve delivered quality
- Prevent recurring errors
- Improve process reliability
- Reduce quality costs
- Enhance customer satisfaction
|
1 day
|
|
Continuous Improvement (Kaizen)
|
- Continuous Improvement concepts
- Overview of improvement techniques
- Direction and empowerment
- Programme management
- Selecting projects
|
- Establish an effective programme
- Provide structure and direction
- Encourage creativity
- Make improvements that support your business strategy
|
1 day
|
|
Team Facilitation Skills
|
- The role of the facilitator
- Motivation - what makes people tick
- Team roles, lifecycle and dynamics
- Interventions
- Handling difficult situations
|
- Nurture team development
- Help teams to learn
- Develop their problem solving skills
- Solve problems quicker at lower cost
- Clarify goals and objectives
- Resolve conflicts constructively
|
1 day
|
|
Integrating Lean and ERP
|
- Principles of Lean and ERP
- The role of planning in Lean
- Integrating ERP and Lean
- 5S applied to information
- Lean information processing
|
- Make Lean and ERP work together
- Plan effectively for Lean production
- Minimise shop-floor paperwork
- Make your data earn its keep
- Streamline administration
|
2 days
|
|
The Lean Supply Chain
|
- Analysing the extended Value Stream
- Identifying waste in the Supply Chain
- Distribution networks and transport
- Warehousing and inventory
- Planning and procurement
|
- Choose the right techniques
- Synchronise material flow
- Improve flexibility and responsiveness
- Improve availability with less inventory
- Reduce waste and costs
|
1 day
|
|
The Lean Office
|
- The Lean "information factory"
- Information flow and pull systems
- Cellular organisation
- 5S in the office
- Quality in the office
|
- Improve flexibility and responsiveness
- Leverage the knowledge and experience of the workforce
- Break down "functional silos"
- Solve problems quicker at lower cost
|
1 day
|
