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