Make Your Organization’s Process Improvement Initiatives Last
Lean is a systematic approach to eliminating waste and creating flow within an organization to improve overall customer value. The foundation for success with lean is a problem-solving culture, based on coordinated process improvement and people development. Leaders from manufacturing, to service industries, to medical organizations have benefited from the techniques pioneered by Toyota. This series of classes teaches not only the tools of lean, but also offers proven leadership techniques for implementing lean in your organization, managing culture change, and developing continuous improvement engagement throughout your workforce. This training will assist companies in saving time, money, and precious resources through creating the most efficient team possible. Benefits of implementing these techniques include coaching and developing team members who actively pursue improvement in safety, quality, productivity, and intentional employee engagement.
- Introduction to Lean & Toyota Kata
- Lean Management System
- 8 Step Problem Solving
- 5S, Standards and Training Within Industry
- Teambuilding & Culture
- Value Stream Mapping
- Quick Changeover
Toyota Kata – Improvement & Coaching:
Leaders need the dual ability to improve processes and develop people to create and sustain a culture of improvement. A Kata is a discipline through which the lean leader serves as a coach/mentor to develop team members. This training introduces the Improvement & Coaching Katas. In the Improvement Kata, participants follow a four-step, scientific pattern which challenges team members to strive for improvement. Through the Coaching Kata, participants learn to follow a mentoring methodology that develops a leader’s skill to coach while simultaneously developing team members’ knowledge. The Kata process is based on the Plan-Do-Check-Act (PDCA) scientific method through which actions are planned, tested, measured, and adjusted towards achievement of a target condition. Teambuilding exercises reinforce the improvement Kata process and the communication skills essential for the Coaching Kata.
Creating a Foundation of Stability and Value Stream Mapping (VSM):
The foundation of Lean is standardization and stability. The 8 wastes are introduced coupled with lean tools & countermeasures. Value Stream Maps provide the Plan in the PDCA improvement cycle. Value-stream mapping gives leaders a picture of the entire production process, both value and non-value-creating activities. The VSM process consists of identifying value streams/product groups, mapping a current state of material and information flow, assessing waste in the process, and designing a desired process. With this knowledge, leaders can direct the application of precious resources toward the creation of a sustainable process and culture.
Leading & Sustaining w/8-Step Problem Solving:
Leading and Sustaining Lean requires a framework of strategic alignment, disciplined culture and operational transparency. The Lean Management System is comprised of elements including process metrics, leader standard work, A3 problem solving, accountability boards, suggestion systems and Gemba walks. This training is designed to provide leaders a disciplined process to foster a problem-solving culture, to build accountability and to reinforce PDCA thinking and management. Combining the Kata process with the Leading and Sustaining Lean system builds the disciplined structure for successful lean implementations. Participants then apply these tools in an exercise that guides them through the problem solving system.
Importance of Standards – 5S, TWI Job Methods & Job Instruction:
The foundation of continuous Improvement is Stability & Standardization. Before a problem – a gap from a standard – can be identified, a standard must be in place. Utilizing a stamping press simulation, participants use the TWI Job Methods questioning process to breakdown the changeover. Stability is introduced via the 5S methodology (Sort, Set-In-Order, Shine, Standardize, and Sustain). PDCA Kata iterations are used to improve towards the target conditions. The 4 step Job Instruction is demonstrated stressing important steps, key points & reasons for key points as the standard for consistency in training methods. This class provides leaders with a structured approach they can apply within their own organizations to reinforce a culture of discipline and process improvement.
Lean Culture & DiSC Profile:
Sustaining a continuous improvement efforts requires defining the company culture and developing team members. The lean philosophy and process must be systematically aligned with the organizations core values in order to seamlessly cultivate a problem solving culture. Lean Culture exposes the participants to the systems necessary to prepare lean leaders, to foster the sustained process of continuous improvement and to permeate continuous improvement throughout the organization. The DiSC profile assessment is used for participants to better understand behavioral and communication preferences within themselves and among others.
Lunch and snacks are included. This class includes two best practice tours of local manufacturers.