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Lean Leader - Body of Knowledge

Build the Lean Culture

  • Lean Organization Structure
  •  Build Continuous Improvement Teams
    • Create a sense of urgency
    • Team stages and team roles
    • Teamwork, team facilitation and team selection
    • Motivation, empowerment & involvement
  • Role of a Change Agent
  • Stakeholder Analysis
  • Handling Resistance

Principles of Lean Improvement

  • Specify Value
  • Process Focus 
  • Identification & Elimination of Barriers to flow
  • 7 Wastes (Muda), Fluctuation (Mura), and Overburden (Muri)
  • Make end-to-end flow visible
  • Manage the flow visually
  • Implement pull
  • Work to perfection

Lean Improvement Systems

  • Lean Improvement Process Methodology - PDCA & DMAIC
  • A3 storyboards
  • Continuous Improvement (Kaizen)

Root Causes Identification Methodologies 

  • Ways to collect Voice of Customer (VOC)
  • Kano Model
  • Translate Voice of Customer (VOC) to Critical to Quality (CTQ)
  • The Gemba Walk 
  • Data Collection and Presentation - Histograms, Pareto Charts, Check Sheets
  • SIPOC, Process Mapping & Value Stream Mapping
  • Spaghetti Diagram and Handoff Map
  • Total Productive Maintenance (TPM)
  • Cause & Effect Diagrams (Fishbone)
  • 5-whys & 5-hows 
  • Failure Mode and Effects Analysis

Lean Improvement Tools

  • Identifying value added/non-value added work
  • Identify waste
  • Cells, one-piece flow
  • Customer Demand Pace (Takt Time)
  • Mistake proofing (poka-yoke)
  • Pull systems (kanban) & Just in Time (JIT)   
  • Visual Workplace - 5S standards and discipline
  • Visual Control 
  • Standard Work
  • Quick Changeover (SMED)
  • Andon System

Theory of Constraints

  • Overview
  • Five Focusing Steps


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