COURSE OVERVIEW
The Lean Organization concept represents a major leap forward in operational efficiency. Popularized by Jim Womack, Daniel Jones, and Daniel Roos in their 1991 book “The Machine That Changed the World”, it inspired companies worldwide to emulate Toyota’s remarkable productivity model.
Lean is all about the systematic elimination of waste — streamlining operations to remove unnecessary “fat” from processes. While it originated in manufacturing, Lean principles have since been successfully applied to administrative, service, and engineering environments, driving quality and performance improvements across all sectors.
KEY FEATURES
The Lean Six Sigma training course offers participants:
- Practical insight into how any organization, not just manufacturers, can achieve Toyota-like efficiency.
- A breakthrough understanding of waste reduction and quality enhancement.
- Proven tools and techniques for maximizing operational efficiency.
- A lasting mindset transformation toward continuous improvement.
- Methods to strengthen both product and service quality initiatives.
LEARNING OBJECTIVES
By the end of this program, participants will be able to:
- Understand the concepts and practical implementation of Lean Organizations.
- Develop working knowledge in Lean and Continuous Improvement methodologies.
- Identify and act on opportunities to reduce waste within their processes.
- Grasp key performance measures such as Cycle Time, Takt Time, and Line Balancing.
- Gain insights into SMED (Single Minute Exchange of Dies) for reducing setup and changeover times.
- Explore flexible production strategies that optimize efficiency.
- Reduce operational time, cost, waste, and quality issues effectively.
TARGET AUDIENCE
This course is designed for personnel at all levels who wish to strengthen their understanding of Lean principles and enhance their ability to apply Lean management techniques effectively within their organizations.
TRAINING METHODOLOGY
The Lean Six Sigma program is highly practical and results-oriented, grounded in adult learning principles.
Participants will engage through interactive discussions, short demonstrations, real-life case studies, role plays, and hands-on exercises.
Ample time is provided for Q&A sessions, group discussions, and personalized action planning to ensure participants can apply their new knowledge directly to their workplace.
Pre- and post-course assessments are conducted to measure participant growth, skill development, and overall course effectiveness.
COURSE MODULES
Module 1: What is Lean and Lean Management?
Description:
Day 1 introduces the foundations of Lean thinking and management through a comprehensive overview and practical examples.
Key Topics:
- What is the Lean Concept?
- Technical and Cultural Aspects of Lean
- The Three Key Dimensions of Lean
Module 2: Understanding Value Add and Waste
Description:
Day 2 explores the difference between activities that create value and those that add unnecessary cost, time, or waste.
Key Topics:
- Defining Value-Adding and Non-Value-Adding Activities
- The Seven Types of Waste
- Depth and Impact of Waste
- Case Exercises: Ratio & Modular Production
- Linking Flexible Production with Waste Reduction
Module 3: Key Tools for Waste Reduction
Description:
Day 3 focuses on core Lean techniques such as Cycle Time, Takt Time, and Line Balancing to enhance productivity without increasing labor costs.
Key Topics:
- Understanding Bottlenecks
- Takt Time and Cycle Time Concepts
- Line Balancing Techniques with Case Exercises
- Developing a Skills Matrix to Improve Worker and Process Efficiency
Module 4: SMED and Total Productive Maintenance (TPM)
Description:
Day 4 dives into SMED and TPM concepts, with practical exercises on improving process changeovers and equipment reliability.
Key Topics:
- Quick Changeover and SMED Principles
- The F1 Case Study
- Internal vs. External Perspectives
- Reducing Changeover, Startup, and Shutdown Times
- Total Productive Maintenance (TPM)
- Preventive vs. Predictive Maintenance
- Overall Equipment Efficiency (OEE)
- Managing Equipment, Time, and Quality Losses
- TPM’s Role in Energy Efficiency
Module 5: Six Sigma
Description:
Day 5 introduces Six Sigma as a complementary approach to quality enhancement, emphasizing precision, process control, and performance improvement.
Key Topics:
- The Three Dimensions of Six Sigma:
- Philosophy
- Statistics
- Process
- DMAIC Methodology:
- Define (with case study)
- Measure (with case study)
- Analyze (with case study)
- Improve (with case study)
- Control (with case study)
