Training program has been designed to be provided in 2 phases.
phase of the Lean Training program, Classroom Training, is built
around the 7 Value Stream Management steps needed to plan, map, and
sustain lean improvements. The seven steps are:
Commit to Lean – this includes assigning a champion and team to a
value stream, and defining the vision and goals for the team through
a project charter prepared by the team and confirmed by management
Choose the Value Stream – this involves targeting a product/product
family (the value stream) to eliminate waste and improve overall
material & information flow
Step 3: Map
the Current State – the team will learn how to prepare a Current
State Value Stream Map.
Identify Lean Metrics – the easiest way to get people to contribute
to Lean initiatives is to give them a simple means of understanding
the impact of their efforts as they improve their value stream. Lean
metrics provide such a means, thus helping to drive continuous
improvement and waste elimination.
Step 5: Map
the Future State – there are 3 stages for future-state mapping;
customer demand, continuous flow, and leveling. In step 5 we
introduce the teams to the bulk of the Lean tools & techniques.
Topics include 5S, Takt Time, Buffer & Safety Inventory, JIT, Line
Balancing, Kanban, Quick Changeovers (SMED), Total Productive
Maintenance (TPM), Paced Withdrawal and Heijunka. These and other
tools will give us the concepts needed to prepare a Future State
Value Stream Map.
Create Kaizen Plans – a kaizen plan is a call to action; the details
of the actions, responsibilities and timelines to achieve the future
state. A key element in this step is to create a Storyboard that
communicates the lean journey; the storyboard is prepared in this
Implement Kaizen Plans – Just Do It! And then document the
improvements achieved in the lean metrics
The second phase is
Application Training, conducted at your facility, where the project
team(s) will apply the 7-step Value Stream Management process that
they have learned in the classroom sessions, under the guidance of
There is typically
between 10 to 15 days of Application Training