Learn more about the principles of Lean Thinking and apply them effectively in your company
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In the constantly changing competitive environment, applying Lean principles and techniques lead to triggering a virtuous process of continuous improvement that enables processes to become more robust and efficient, to make companies more responsive and able to effectively meet market changes.
In a modern company, it is strategic to develop Lean Expert skills across all roles to Create and disseminate a common language and operational culture of excellence.
Objectives of the course
- Know the principles of Lean Thinking and be able to apply them in the context of business processes and contextualize them in their own reality
- Know how to read activities in terms of Customer Value and acquire techniques to identify and eliminate waste
- Define and know how to calculate the most appropriate indicators to measure business performance in terms of Safety, Service, Quality and Productivity
- Set up and effectively lead improvement activities (Kaizen) by leading a work group using A3
Learning By Doing
In the Lean Expert track, with Experiential Training involving simulations, Role Playing Game and practical exercises, participants will be able to:
- Represent business processes through the Value Stream Mapping methodology to analyze the current situation (AS-IS), identify critical issues, and define a Future State Map (TO-BE)
- Acquire methods and techniques for effective and efficient problem solving with a team
- Making workstations and work environments more functional by analyzing activities at VA and at NVA, and the methodology of the 5S and Visual Management
- Measuring the performance of processes, machines, and plants, identifying the main losses in order to systematically attack them
- Apply techniques to analyze and reconfigure the balancing of production lines and flows, according to the Takt Time required by the market
- Use the technique SMED To optimize format changes
- Define an Autonomous Maintenance plan
The format
- Prework: Online test to assess the level of basic knowledge
- Training with learning by doing sessions
- Tutoring: support for the selection and conduct of project work in the company
- Certification:
- Final Test
- Project Work presentation for certification of acquired skills
- Delivery Certificate
Course Schedule.
Learn about all of the Course Modules here
Lean Problem Solving: solving problems effectively and efficiently
- Defining a problem
- The Steps of Problem Solving
- The problem setting:
- Description
- Pareto and stratification
- Goal setting and indicators
- The methodology of analysis: the PDCA
- Root cause analysis through survey instruments (6M to 5 Why)
- Proper definition of targets and objectives
- The consolidation of achievements: standardization and training through SOP (Standard Operating Procedure) and OPL (One Point Lesson)
Managing a project: delving into the techniques and tools of managing resources in a project efficiently
- Project phases and the 5 Lean principles
- Lean PUSH VS PULL Approach
- Definition of project objectives
- Sizing Resources: rules and principles
- Project Charter: Project form structure and filling out
- Visual planning tools short, medium and long term
- WBS (Work Breakdown Structure)
- Stage & Gate
The concept of flow and its balance
- Methods and tools for materials management in production areas (Synchro logic and Kit system; Kanban logic and Supermarket sizing with Pull System)
- Where and why the flow does not flow: Push, Pull, Takt time, One Piece flow
Session simulative: real assembly of products in island configuration and calculation of indicators
- How to balance production flows
- The daily improvement of production performance: the Flash Meeting
- Application of improvements and rebalancing of assembly flow
Session simulative: Mounting of products in configuration line With assistance from digital systems
OEE and Shop Floor Management: how to improve through production data
- Introduction on the principles of TPM
- The OEE indicator and how to measure it
- Machine and plant production losses, their classification and aggregation
Session simulative: work shift simulation on plant, collection of losses and OEE indicator calculation
- Training on the use of Shop Floor Management tools and daily meeting simulation for loss attack
- Proposed improvement actions to resolve top5 leaks and actual implementation
- Digital capture of machine status, with recording of times and types of losses
Session simulative: Application of improvement ideas and automatic OEE recalculation with data collected and reclassified into via digital.
5S and Visual Management: lo Visual standard as a basic tool for discipline and improvement
- Introduction to the 5S methodology
- The indicators of workplace efficiency
- How to recognize workplace inefficiency and propose improvements
Session simulative: identification of waste and inefficiencies of the workstation on assembly benches
- Application of 5S, one S at a time, to understand achievable improvements
Session simulative: Implementation of proposed improvements and calculation of indicators
SMED: production change as an opportunity for improvement
- Introduction on SMED objectives and methodology to reduce and simplify production changeover time
- Production change matrix training session: how to choose a representative production change
Simulative session: Execution of change Movie production on a real machine with anomaly collection
- Training on SMED principles and tools, chronotechnical analysis of setup sequence
- Proposing ideas for improvement and streamlining change activities
Simulative session: Testing the new shifting procedure on a real machine and comparing the results obtained
Autonomous Maintenance (AM): clean and Inspect to increase efficiency
- Introduction on the objectives and key concepts of Autonomous Maintenance
Session simulative: Conduction of a production facility and identification of the lack of basic conditions
- Communicate in an organized way to solve problems (the Visual tag) even after the construction phase
- Attacking leakage due to lack of basic conditions of a plant and implementing proposed solutions
- Creating operational standards based on Visual Management and ensuring maintenance and improvement through operational procedures and tools
Session simulative: Implementation standard start/end of work to ensure work efficiency
Value Stream Mapping: Identifying and mapping as-is and to-be value
Simulative session: group exercise on value stream mapping
- The Lean World Class® Approach.
- Provide a clear and comprehensive view of flows for a product family
- Highlight the connection between the flow of materials and the flow of information
- Calculate the Flow Index
- Identifying waste: Not Value Added Activities (NVAA or "muda")
- Introduction to the use of Lean methodology and its Lean tools (Kanban, 5S, JIT, TPM, SMED, ...)
- Creating a Future State Map, reducing existing waste
- Checking the improvements made by applying the methods learned in the previous days
Project Work
- Support for the selection of Project Work to be carried out independently in the company and completion of the relevant project A3
Register to download the Summary Course Sheet
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