Introduction:

Lean Management is a philosophy focused on minimizing waste, improving process efficiency, and maximizing customer value. While traditional Lean methods focus on core principles such as value stream mapping and the 5S system, advanced Lean techniques build on these foundations to address more complex challenges in today’s fast-paced business environments. This course provides an advanced understanding of Lean strategies, equipping participants with the tools to drive systemic, sustainable improvements across processes, reduce inefficiencies, and foster a culture of continuous improvement. Participants will learn cutting-edge Lean techniques that are critical to maintaining competitiveness and agility in modern organizations.

Course Objectives:

By the end of this course, participants will:

1. Understand advanced Lean principles and how to apply them for maximum impact in complex organizational settings.
2. Gain proficiency in advanced Lean tools such as Value Stream Mapping (VSM), Kaizen, Just-in-Time (JIT), and Lean Six Sigma integration.
3. Learn how to identify and eliminate root causes of waste and inefficiency at the organizational, departmental, and process levels.
4. Develop strategies to engage employees at all levels in Lean initiatives and sustain improvements over time.
5. Master techniques for integrating Lean management with other quality management methodologies, including Six Sigma.
6. Be equipped to lead Lean transformation initiatives and create a culture of continuous improvement within their organization.

Who Should Attend?

This course is ideal for:

• Lean Managers and Leaders
• Senior Executives and Business Managers
• Continuous Improvement Professionals
• Six Sigma Green Belts and Black Belts
• Operations and Production Managers
• Quality Managers and Analysts
• Project Managers involved in Lean or process improvement projects
• Consultants or trainers supporting Lean initiatives
• Anyone responsible for driving Lean transformations and improving process efficiency

Day-by-Day Outline:

Day 1: Introduction to Advanced Lean Principles and Concepts

• Review of Lean Basics: A quick review of core Lean principles, including value stream mapping, waste elimination, and the 5S system
• The Evolution of Lean Management: How Lean principles have evolved and how advanced techniques are shaping the future of business processes
• The Role of Leadership in Lean Transformation: How top-down and bottom-up leadership contribute to Lean success
• Advanced Lean Philosophy: Delving into Lean Thinking, Lean Leadership, and Lean Culture for continuous improvement
• Value Stream Mapping (VSM) – Advanced Concepts: Techniques for analyzing and mapping complex value streams in multi-department or cross-functional processes
• Types of Waste Beyond the 7 Wastes: Identifying and tackling waste in more nuanced areas such as information flow, talent, and innovation processes
• Case Study: Analyzing a real-world case of a Lean transformation using advanced principles
• Group Discussion: How advanced Lean principles can be applied to specific business challenges

Day 2: Advanced Lean Tools and Techniques

• Kaizen and Kaizen Blitz: Advanced Kaizen techniques for driving rapid and sustained improvements through focused events and continuous innovation
• Just-in-Time (JIT) Systems: Advanced JIT concepts and their application in reducing lead time and optimizing inventory management
• Takt Time and Flow Efficiency: Understanding takt time, balancing workstations, and improving flow efficiency in complex systems
• Standardized Work and Workflows: Creating and implementing standardized processes and workflows to drive consistency and eliminate variation
• Poka-Yoke (Mistake Proofing): Advanced techniques for designing processes that prevent errors and defects from occurring
• Lean Metrics and KPIs: How to measure the impact of Lean initiatives with advanced performance indicators such as Overall Equipment Effectiveness (OEE), First-Time Quality (FTQ), and cycle time reduction
• Total Productive Maintenance (TPM): Integrating TPM into Lean for maintaining equipment efficiency and reducing downtime
• Hands-On Activity: Developing a process improvement using Kaizen Blitz and JIT systems for a simulated business challenge

Day 3: Lean and Six Sigma Integration

• Lean and Six Sigma Synergy: How Lean and Six Sigma complement each other to optimize both speed and quality across processes
• DMAIC in Lean: Integrating Lean principles with the DMAIC (Define, Measure, Analyze, Improve, Control) methodology for complex problem-solving
• DFSS (Design for Six Sigma) and Lean: Combining Lean’s efficiency focus with Six Sigma’s quality control for designing processes that meet customer expectations from the outset
• Advanced Value Stream Mapping (VSM) with Six Sigma Metrics: Combining VSM with Six Sigma tools like control charts and hypothesis testing to measure process performance and improvements
• Lean Metrics vs. Six Sigma Metrics: Understanding the differences and how to use both for effective decision-making
• Failure Modes and Effects Analysis (FMEA): Conducting FMEA to prevent defects and optimize Lean implementations
• Lean Six Sigma Case Study: Analyzing a successful Lean Six Sigma project in a real-world setting
• Group Activity: Combining Lean and Six Sigma methodologies in a case study to optimize a process

Day 4: Leading Lean Transformation and Sustaining Results

• Creating a Lean Culture: Developing and nurturing a Lean culture across the organization through employee engagement and empowerment
• Lean Leadership Practices: Key leadership skills and behaviors required to drive a successful Lean transformation
• Employee Involvement and Continuous Improvement: Creating a system for encouraging suggestions, problem-solving, and idea-sharing at all levels
• Resistance to Lean: Identifying and overcoming common barriers to Lean adoption, including cultural resistance, lack of resources, and insufficient training
• Developing and Training Lean Teams: Building effective cross-functional Lean teams and developing training programs for continuous skill-building
• Change Management and Lean: Managing the human side of Lean transformations to ensure that improvements are sustained
• Leadership Roundtable: Senior leaders discuss best practices and common challenges in leading Lean transformations
• Action Plan Development: Creating a personalized action plan for leading Lean initiatives within the participant’s own organization

Day 5: Advanced Lean Applications and Future Trends

• Lean in Service and Knowledge Work: Extending Lean principles beyond manufacturing into service, healthcare, and knowledge-based industries
• The Role of Technology in Lean: Exploring the integration of digital tools, IoT, AI, and automation in Lean management
• Sustainability and Lean: How Lean principles can be aligned with environmental and sustainability goals to drive long-term value
• Lean and the Supply Chain: Advanced strategies for optimizing supply chains using Lean principles, including demand forecasting, supplier collaboration, and logistics optimization
• Lean for Innovation: Using Lean to drive innovation and create a culture of creative problem-solving
• Future of Lean: Understanding emerging trends such as Industry 4.0 and how Lean will continue to evolve in the future
• Review and Course Wrap-Up: Reflecting on the key lessons learned throughout the course and reviewing participant action plans for Lean implementation
• Final Exam: A comprehensive test covering advanced Lean tools, techniques, and concepts