Day One: Lean Principles

Lean Concept and Objectives

• Reducing waste and increasing efficiency in operations.
• Improving quality and achieving customer satisfaction.
• Enhancing speed and flexibility in organizational performance.

Types of Waste (7 Wastes)

• Waste of time (Waiting).
• Inventory and material waste (Inventory).
• Motion and over-processing waste.

Core Value Principles

• Focus on customer-added value.
• Eliminate non-value-added activities.
• Improve workflow for smooth and effective operations.

Day Two: Lean Tools for Operations Improvement

Value Stream Mapping (VSM)

• Documenting current process steps.
• Analyzing waste and delay points.
• Designing the future-state optimized process.

Continuous Improvement Tools

• Kaizen for gradual continuous improvement.
• 5S for workplace organization and efficiency.
• Poka-Yoke for error prevention.

Organizational Performance Management

• Defining key performance indicators (KPIs).
• Monitoring improvements and their impact on results.
• Linking performance to rewards and motivation.

Day Three: Applying Lean to Operations

Analyzing Current Processes

• Collecting data and monitoring performance.
• Identifying bottlenecks and inefficient processes.
• Evaluating each step’s contribution to final value.

Designing Improved Processes

• Redesigning processes to reduce waste.
• Integrating similar activities for higher efficiency.
• Creating a phased implementation plan for improvements.

Sustaining Improvement

• Building a culture of continuous improvement within teams.
• Tracking performance indicators after changes.
• Sharing successes and lessons learned to ensure sustainability.