Lean Modules

Several modules focusing on Lean methodologies are offered to help students become Lean Leaders.

  • Lean Overview
  • 5S & Visual Mgmt
  • Problem-Solving Tools
  • Team Building

The Lean Overview module is the beginning of your journey toward world-class and provides the answers to your questions on Lean. It provides a basic understanding of Lean methodology and the tools used to support Lean initiatives. This new approach to thinking and learning supports the paradigms that we hope for: creating vibrant, healthy, competitive, world-class companies that optimize people, processes, and resources to succeed globally and build wealth for stakeholders. This is a quantum leap in the application of Lean training and methodology: don’t just be Lean – be vibrant, healthy, and fit. The module includes a hands-on simulation that shows how Lean improves production processes.

Upon completion of Lean Overview, participants will be able to:

  • Understand and define the principles of Lean
    • What is Lean?
    • What is the origin of Lean?
    • What are the principles of Lean?
    • How does Lean work as an integrated system?
    • What are the Eight Wastes that Lean targets?
    • How can I implement Lean in my organization?
  • Understand how Lean methodology supports your business initiatives
  • Apply Lean principles in a simulation model

** Lean Overview is a prerequisite for most Lean Modules.

The 5S and Visual Management module is designed for participants to learn why 5S is the foundation of Lean principles. It engages employees and builds excitement for the change process in your organization. 5S/Visual Management implementation leads to pride in the workplace while sustaining improvements for cleanliness, organization, and safety. The entire 5S/Visual Management process is covered in this module, from initial communication to all employees through implementation and process auditing.

Prerequisite: Lean Overview

Topics include:

  • Comprehensive description of 5S (Sorting, Straightening, Sweeping, Standardizing, Sustaining)
  • Why it is important to implement 5S
  • The five steps of implementation
  • Tools and techniques for implementation
  • Red tagging strategies
  • The keys to long-term 5S success
  • Application of Visual Management practices
  • Using visual standards for everyone
  • Decision-making at a glance
  • Typical examples of Visual Management

Upon completion, you will be able to:

  • Define each 5S
  • Describe how 5S activities are linked to bottom-line measurements
  • Deploy and sustain a 5S program
  • Use visual signals to speed the decision-making process

The Problem-Solving Tools module presents an eight-step process covering basic problem-solving tools with a critical element – application of the tools. You will gain an understanding of the appropriate application and effective use of each tool. In addition, the tools will be practiced using real examples that you provide. Application of group decision making (brainstorming, multivoting and consensus) to identify and analyze problems will also be incorporated.

Prerequisite: Lean Overview

Topics include:

  • Root Cause Analysis
  • Identifying problems
  • Analyzing problems
  • Familiarization with Root Cause Analysis, Process Flowcharting, Pareto Chart, Fishbone Diagram, Histogram, Scatter Diagram
  • Utilizing multiple tools on a single problem
  • Application of the tools through an in-class, hands-on simulation

Upon completion, you will be able to:

  • Effectively identify and select problems for resolution
  • Select the most effective tool to use for specific problems
  • Interpret the information gained from the tool to begin developing a corrective action plan

The Team Building module addresses how groups can become effective decision-making teams. You will increase your awareness and understanding of attributes of high-performance teams, needs of a team, and ways to overcome challenges teams face to work more effectively together to deliver results. The module includes applying course material in a team building exercise.

Prerequisite: None

Topics include:

  • What is a team?
  • Types of teams
  • Elements of a winning team
  • Aspects and benefits of high-performance teams
  • What do high performance teams need from managers/companies in the way of support to succeed?
  • Understanding team dynamics
  • What stages do teams go through
  • Types of team building
  • Understanding your team styles
  • Barriers to effective teams
  • Five dysfunctions of a team
  • Evaluating team performance

Upon completion, you will be able to:

  • Understand how teams can effect an organization’s performance
  • Know the stages of a team’s development
  • Understand the five dysfunctions of teams
  • Define the characteristics that make a winning team
  • Understand what high-performance teams are
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