Lean Management

Day 1: Introduction to Lean Management


1. Welcome and Course Introduction

   - Introduction to the trainer and participants

   - Overview of the course structure and objectives

   - Importance and benefits of Lean Management



2. Fundamentals of Lean Management

   - History and evolution of Lean Management

   - Key principles and concepts of Lean

   - Comparison with traditional management practices



3. Lean Thinking and the Lean Philosophy

   - Understanding Lean thinking and mindset

   - The Five Lean Principles (Define Value, Map Value Stream, Create Flow, Establish Pull, Seek Perfection)

   - Lean culture and its impact on organizational success



4. Value Stream Mapping

   - Introduction to value stream mapping

   - Steps to create a value stream map

   - Identifying value-added and non-value-added activities



5. Identifying and Eliminating Waste

   - The seven types of waste (overproduction, waiting, transport, extra processing, inventory, motion, defects)

   - Techniques for identifying waste in processes

   - Strategies for waste elimination



6. Lean Tools and Techniques

   - Overview of essential Lean tools (5S, Kaizen, Kanban, Poka-Yoke, SMED)

   - Practical applications and examples




 Day 2: Implementing Lean Practices


1. Lean Implementation Strategy

   - Developing a Lean implementation plan

   - Key steps and considerations for successful Lean adoption

   - Role of leadership in driving Lean initiatives



2. Process Improvement Techniques

   - Continuous improvement and the PDCA cycle (Plan-Do-Check-Act)

   - Root cause analysis and problem-solving techniques (5 Whys, Fishbone Diagram)

   - Process standardization and documentation



3. 5S Workplace Organization

   - Introduction to 5S (Sort, Set in order, Shine, Standardize, Sustain)

   - Benefits of a well-organized workplace

   - Practical steps to implement 5S



4. Kaizen and Continuous Improvement

   - Understanding the Kaizen philosophy

   - Conducting Kaizen events and workshops

   - Engaging employees in continuous improvement initiatives



5. Lean Metrics and Performance Measurement

   - Key performance indicators (KPIs) for Lean

   - Using metrics to track and improve performance

   - Visual management and performance boards



 Day 3: Sustaining Lean and Advanced Topics 


1. Lean Leadership and Culture

   - Characteristics of Lean leaders

   - Building and sustaining a Lean culture

   - Role of leadership in empowering and motivating teams



2. Advanced Lean Tools and Techniques

   - In-depth look at advanced Lean tools (Hoshin Kanri, Value Stream Mapping for Future State, Lean Six Sigma)

   - Case studies and real-world applications



3. Lean in Various Sectors

   - Applications of Lean in manufacturing, services, healthcare, and other industries

   - Examples and success stories



4. Overcoming Challenges in Lean Implementation

   - Common obstacles and resistance to Lean

   - Strategies for overcoming challenges

   - Change management principles



5. Lean Project Simulation

   - Hands-on simulation exercise

   - Applying Lean principles to a mock project

   - Debrief and lessons learned



6. Final Q&A and Course Conclusion

   - Open discussion and final questions

   - Course summary and key takeaways

   - Feedback and evaluations