Week 1: Introduction to Proactive Lean Management

Learning Objectives:

Understand the basic principles of lean management. You will learn to recognize the importance of lean management in improving efficiency and reducing waste. Finally, you will be able to Identify potential workplace improvement areas.

Key Learning Points:

• Introduction to lean management principles.
• Overview of waste identification and elimination.
• Importance of employee involvement in lean management.

Training Outcome: Participants will have a foundational understanding of lean management principles and their relevance to the workplace.

Practical Assignment: Conduct a waste audit in your department and identify three areas for improvement.

Skills Development: Observation, problem identification, critical thinking.

Week 2: Value Stream Mapping

Learning Objectives: Learn how to create value stream maps to visualize and analyze processes, Identify value-adding and non-value-adding activities, and understand how value stream mapping can lead to process improvement.

Key Learning Points:

• Purpose and benefits of value stream mapping.
• Steps to create a value stream map.
• Analyzing current state vs. future state value stream maps.

Training Outcome: Participants will be able to create and interpret value stream maps to identify areas for improvement.

Practical Assignment: Create a value stream map for a critical process in your department and propose improvements for the future state.

Skills Development: Process analysis, data visualization, problem-solving.

Week 3: 5S Workplace Organization

Learning Objectives: The student will understand the principles of 5S: Sort, Set in Order, Shine, Standardize, and Sustain. The participant will also learn how to implement 5S in the workplace to improve organization and efficiency. Simultaneously, they will recognize the benefits of a clean and organized work environment.

Key Learning Points:

• Overview of each of the 5S principles.
• Techniques for implementing 5S in different workplace settings.
• Importance of sustaining 5S practices.

Training Outcome: Participants will have the knowledge and skills to implement 5S in their work areas.

Practical Assignment: Conduct a 5S audit in your workspace and develop a plan for sustaining 5S practices.

Skills Development: Organization, attention to detail, teamwork.

Week 4: Initiation to Kaizen Continuous Improvement

Learning Objectives: This training module will address the Kaizen Concept and its role in lean management. Afterward, the participant will learn how to facilitate Kaizen events for process improvement. In addition, the student will explore strategies to identify opportunities for continuous improvement in the workplace.

Key Learning Points:

• Definition and principles of Kaizen.
• Steps to plan and conduct a Kaizen event.
• Strategies for sustaining continuous improvement efforts.

Training Outcome: Participants can lead and participate in Kaizen events to drive continuous improvement.

Practical Assignment: Plan and facilitate a Kaizen event for a process improvement initiative in your department.

Skills Development: Leadership, facilitation, collaboration.

Week 5: Just-in-Time (JIT) Production

Learning Objectives: The student will unlock and be briefed on Just-in-Time Production concepts. Consequently, the participant will learn how the JIT Principles can reduce waste and improve efficiency. Apart from that, they will explore how to identify strategies for implementing JIT in manufacturing and service environments.

Key Learning Points:

• Principles of JIT production.
• Techniques for implementing JIT, such as Kanban and pull systems.
• Benefits and challenges of JIT implementation.

Training Outcome: Participants will understand the principles of JIT production and be able to identify opportunities for implementation in their workplace.

Practical Assignment: Analyze a production process and propose JIT strategies to reduce inventory and improve flow.

Skills Development: Process analysis, inventory management, problem-solving.

Week 6: Total Productive Maintenance (TPM)

Learning Objectives: The training will focus on Total Productive Maintenance (TPM) principles. For example, the student will learn how TPM can improve equipment reliability and productivity. In addition, they will identify strategies for implementing TPM in the workplace.

Key Learning Points:

• Principles of TPM.
• Components of an effective TPM program.
• Techniques for maximizing equipment effectiveness.

Training Outcome: Participants will understand the importance of TPM in lean management and be able to implement TPM strategies in their workplace.

Practical Assignment: Develop a TPM plan for a critical piece of equipment in one department.

Skills Development: Equipment maintenance, reliability engineering, teamwork.

Week 7: Error Proofing (Poka-Yoke)

Learning Objectives: The student will fully understand the concept of Error-Proofing and its importance in lean management. For instance, they will master how to identify and implement Poka-Yoke solutions. Further, the participant will recognize the benefits of error-proofing in preventing defects and improving quality.

Key Learning Points:

• Definition and principles of error-proofing.
• Techniques for implementing Poka-Yoke solutions.
• Examples of error-proofing in different industries.

Training Outcome: Participants will be able to identify opportunities for error-proofing in their processes and implement Poka-Yoke solutions.

Practical Assignment: Identify potential error points in a process and propose Poka-Yoke solutions to prevent errors.

Skills Development: Quality management, attention to detail, and problem-solving.

Week 8: Kanban Board and Status Management

Learning Objectives: The training program participant will uncover the importance of Visual Management in lean environments, learn how to create visual controls to communicate information effectively, and identify opportunities for implementing visual management in the workplace.

Key Learning Points:

• Principles of visual management.
• Techniques for creating visual controls, such as visual displays and signage.
• Benefits of visual management in improving communication and efficiency.

Training Outcome: Participants can implement visual management techniques to improve workplace organization and communication.

Practical Assignment: Create a visual management board for your department to track key performance metrics.

Skills Development: Communication, information design, creativity.

Week 9: Standard Work Best Practices

Learning Objectives: The student will be educated and trained on standard work and its importance in lean management. They will also learn how to develop and implement standardized work procedures and recognize the benefits of standard work in improving consistency and efficiency.

Key Learning Points:

• Definition and principles of standard work.
• Steps to develop and document standardized work procedures.
• Techniques for training employees on standard work.

Training Outcome: Participants can develop and implement standardized work procedures in their departments.

Practical Assignment: Document standard work procedures for a critical process in your department and train team members on the new procedures.

Skills Development: Process documentation, training, consistency.

Week 10: Root Cause Analysis

Learning Objectives: This module will emphasize the importance of root cause analysis in problem-solving, learn different techniques for identifying root causes of problems, and develop skills in conducting practical root cause analysis.

Key Learning Points:

• Definition and importance of root cause analysis.
• Techniques for identifying root causes, such as fishbone diagrams and 5 Whys.
• Steps to conduct a thorough root cause analysis.

Training Outcome: Participants will be able to identify and address the root causes of workplace problems effectively.

Practical Assignment: Conduct a root cause analysis for a recurring problem in your department and propose solutions to address the root causes.

Skills Development: Problem-solving, critical thinking, and analytical skills.

Week 11: Gemba Walks

Learning Objectives: Understand the concept of Gemba and its importance in lean management, learn how to conduct effective Gemba walks to observe processes firsthand and recognize the benefits of Gemba walks in promoting continuous improvement.

Key Learning Points:

• Definition and purpose of Gemba walks.
• Techniques for conducting Gemba walks, including observation and questioning.
• Strategies for implementing Gemba walks in the workplace.

Training Outcome: Participants will be able to conduct Gemba walks to identify opportunities for improvement in their work areas.

Practical Assignment: Conduct a Gemba walk in your department and identify at least three areas for improvement.

Skills Development: Observation, communication, continuous improvement mindset.

Week 12: Policy Deployment or “Hoshin Kanri”

Learning Objectives: The student will gain insights into the principles of Hoshin Kanri and its role in lean management, learn how to develop and deploy strategic objectives throughout the organization, and Identify strategies for implementing Hoshin Kanri in the workplace.

Key Learning Points:

• Definition and principles of Hoshin Kanri.
• Steps to develop and deploy strategic objectives using Hoshin Kanri.
• Techniques for aligning individual goals with organizational objectives.

Training Outcome: Participants will understand how to develop and deploy strategic objectives using Hoshin Kanri to drive organizational improvement.

Practical Assignment: Develop a Hoshin Kanri plan for your department, including strategic objectives and action plans.

Skills Development: Strategic planning, goal setting, alignment.

Week 13: Lean and Proactive Leadership

Learning Objectives: This time, the student will receive specialized training and education on lean leadership principles and their importance in driving change, how to lead and support lean initiatives within the organization, and how to recognize the characteristics of influential lean leaders.

Key Learning Points:

• Definition and principles of “Lean Leadership.”
• Techniques for leading lean initiatives, including coaching and empowerment.
• Characteristics of influential lean leaders and how to develop them.

Training Outcome: Participants will understand the role of lean leadership in driving organizational change and be able to apply lean leadership principles in their roles.

Practical Assignment: Identify opportunities to demonstrate lean leadership behaviors in your daily interactions with team members.

Skills Development: Leadership, communication, empowerment.

Week 14: Lean Culture and Employee Engagement

Learning Objectives: Each student will study the importance of a lean culture in sustaining lean practices while learning strategies for creating a continuous improvement culture and recognizing employee engagement’s role in lean management.

Key Learning Points:

• Definition and characteristics of a lean culture.
• Techniques for fostering employee engagement and ownership.
• Strategies for sustaining a culture of continuous improvement.

Training Outcome: Participants will understand how to create and sustain a lean culture and engage employees in continuous improvement efforts.

Practical Assignment: Develop a plan to promote employee engagement and foster a culture of continuous improvement in your department.

Skills Development: Culture building, employee engagement, change management.

Week 15: Lean Metrics and Performance Measurement

Learning Objectives: In this module, the participants will discover the importance of metrics in measuring lean performance, learn to select and track key performance indicators (KPIs) in a lean environment, and recognize the role of performance measurement in driving improvement.

Key Learning Points:

• Definition and purpose of lean metrics.
• Techniques for selecting and tracking KPIs.
• Strategies for using performance measurement to drive improvement.

Training Outcome: Participants can select and track key performance indicators to measure and drive department improvement.

Practical Assignment: Identify relevant KPIs for your department and develop a performance measurement dashboard to track them.

Skills Development: Data analysis, performance measurement, goal setting.

Week 16: Lean Six Sigma Overview

Learning Objectives: This classic Lean Management subject matter is the cornerstone for students to familiarize themselves with the principles of Lean Six Sigma and its role in process improvement, learn about the DMAIC (Define, Measure, Analyze, Improve, Control) methodology, and recognize the benefits of combining lean and Six Sigma principles.

Key Learning Points:

• Overview of Lean Six Sigma principles.
• Introduction to the DMAIC methodology.
• Benefits of integrating lean and Six Sigma approaches.

Training Outcome: Participants will have a foundational understanding of Lean Six Sigma principles and methodologies.

Practical Assignment: Identify a process improvement project in your department and outline a plan for applying the DMAIC methodology.

Skills Development: Process improvement, problem-solving, and project management.

Week 17: Lean Tools and Techniques

Learning Objectives: This advanced module addresses the following objectives: Learn about various lean tools and techniques for process improvement, understand how and when to apply different lean tools, and recognize the benefits of using lean tools in problem-solving.

Key Learning Points:

• Overview of standard lean tools, such as 5S, Kanban, and Poka-Yoke.
• Techniques for applying lean tools in different situations.
• Examples of successful lean tool implementation in various industries.

Training Outcome: Participants will be familiar with various lean tools and techniques and understand how to apply them.

Practical Assignment: Select a lean tool or technique and apply it to a process improvement project in your department.

Skills Development: Tool application, problem-solving, creativity.

Week 18: Lean Project Management

Learning Objectives: The module will examine lean project management principles, learn how to apply lean principles to project management processes, and recognize the benefits of lean project management in delivering projects more efficiently.

Key Learning Points:

• Overview of lean project management principles.
• Techniques for applying lean principles to project planning, execution, and monitoring.
• Strategies for managing lean projects effectively.

Training Outcome: Participants will understand how to apply lean principles to project management and deliver projects more efficiently.

Practical Assignment: Develop a lean project plan for a process improvement initiative in your department.

Skills Development: Project management, planning, execution.

 Week 19: Lean Supply Chain Management

Learning Objectives: This exciting module will discuss and teach the principles of lean supply chain management, how to apply lean principles to optimize supply chain processes, and recognize the benefits of lean supply chain management in improving efficiency and reducing waste.

Key Learning Points:

• Overview of lean supply chain management principles.
• Techniques for optimizing supply chain processes, such as supplier collaboration and demand-driven replenishment.
• Strategies for implementing lean supply chain practices.

Training Outcome: Participants will understand how to apply lean principles to optimize supply chain processes and reduce waste.

Practical Assignment: Identify opportunities for improvement in the supply chain processes within your organization and propose lean solutions.

Skills Development Supply chain management, collaboration, optimization.

Week 20: Lean Sustainability and Continuous Improvement

Learning Objectives: The student will recognize the importance of sustainability in lean management, learn strategies for sustaining lean practices over the long term, and recognize the role of continuous improvement in maintaining competitiveness.

Key Learning Points:

• Importance of sustainability in lean management.
• Techniques for sustaining lean practices include regular audits and employee training.
• Strategies for fostering a culture of continuous improvement.

Training Outcome: Participants will understand how to sustain lean practices and foster a culture of continuous improvement in their organization.

Practical Assignment: Develop a sustainability plan for lean practices in your department, including strategies for ongoing improvement.

Skills Development: Sustainability planning, continuous improvement, adaptability.

CONCLUSION:

This 20-week comprehensive training program covers various topics and provides participants with practical knowledge and skills to implement lean management practices effectively and proactively in their workplace.

Each module includes these five sections to ensure participants can apply their knowledge in their daily workplace activities.

• Learning Objectives,
• Key Learning Points
• Training Outcomes,
• Applicable Assignments
• Skills Development