Lean Process Improvement Course Outline

Lean Process Improvement

How to Use This Guide

Session One: Course Overview

Session Two: Understanding Lean

Defining Lean

The History of Lean

Lean vs. Six Sigma

Pre-Assignment Review

A Lean Glossary

Session Three: The Toyota Production System

Overview of the Liker Pyramid

Exploring the Philosophy

Considering the Processes

Understanding People and Partners

Problem Solving Tools

Session Four: The Toyota Production System House

Session Five: The Five Critical Improvement Concepts

Key Ideas

Case Study

Session Six: Understanding Value with the Kano Model

Session Seven: Types of Waste

The Three Categories

Making Connections

Session Eight: Creating a Lean Enterprise

Going Green with Lean

The Characteristics of a Lean Organization

Session Nine: The Plan, Do, Study, Act (PDSA) Cycle

Session Ten: Using the R-DMAIC-S Model

Session Eleven: Lean Thinking Tools


Genchi Genbutsu and Gemba

Performing a 5-S

Session Twelve: Kaizen Events

About Kaizen and Kaizen Events

Typical Kaizen Blitz Workflow

Personal Reflection

Session Thirteen: Data Gathering and Mapping

Flow Charts

Making Breakfast

Ishikawa (Cause and Effect) Diagrams

SIPOC Diagrams

Value Stream Maps

Tips for Effective Data Analysis

Session Fourteen: A Plan to Take Home

Roadblocks and Pitfalls

Creating a Successful Organizational Structure

Where To Get Started?

A Plan for Success

Recommended Reading List

Post-Course Assessment

Pre- and Post-Assessment Answer Keys

Personal Action Plan