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KAIZEN - - FOUNDATION FOR LEAN PRACTICES
   
iNTRODUCTION :
 
 

In today’s competitive global economy, organizations need to operate more effectively by increasing productivity, improving quality, and reducing wastes.  LEAN Manufacturing or LEAN Practices is a business model and collection of tactical methods that emphasize eliminating non-value added activities (waste) while delivering quality products on time at the least cost with greater efficiency.  Worldwide, Lean implementation is rapidly expanding throughout diverse manufacturing and service sectors such as aerospace, automotive, electronics, furniture production, and healthcare as a core business strategy to create a competitive advantage. Lean techniques often create a culture of continuous improvement, employee empowerment, and waste minimization, which will benefit the organization and society at large.

The Japanese word, KAIZEN, means ‘continuous improvements and process innovation’, a powerful philosophy & operational strategies that have proven successful worldwide.  The most attractive factor is that KAIZEN practices, once implemented in the workplace, it provides a commonsense, low-cost approach to continuous improvement strategy. It can be practiced by anyone in the workplace without much investment in sophisticated tools or technologies.  Another benefit of KAIZEN practices is that it fuels group learning of fundamental values derived from common sense, self-discipline, order, and economy that all workers must adopt in solving problems.  KAIZEN practices lay the foundation for Lean Manufacturing & Total Quality Management (TQM).

Before implementing LEAN Manufacturing or LEAN Practices, all levels of employees should attend this foundational training program. This training program is specially designed for organizations that wish to start with a strong KAIZEN foundation (the basic disciplines) for successful Lean implementation in the organization. It expounds the KAIZEN philosophy, concepts and methods including its practical applications that make Toyota Production Systems (TPS) as the most sought-after strategies worldwide for LEAN excellence. It is a practical approach to implement a KAIZEN programs in the workplace.

COURSE OBJECTIVES:

At the end of the course, participants will be able to:

  • Recognize the overall benefits of Lean Manufacturing practices in the organization.
  • Identify the stages of Lean Manufacturing implementation.
  • Describe KAIZEN’s principles, approach, methods, and differentiate between the Traditional and KAIZEN practices.
  • Explain the importance of 5S: Five Steps of Workplace Organization
  • Practice Visual Management in the 5Ms (Man, Machines, Materials, Methods, Measurements).
  • Identify and eliminate MUDA (wastes) - - any non-value-adding activity.
  • Make suggestions for POKA-YOKE (Fail-proofing) implementations at the workplace
  • Assist your management to implement the Foundation of Lean Manufacturing practices in the organization and avoid common pitfalls of its implementation
course METHODOLOGY:

In order to engage the participants for maximum learning and retention, this course uses the following methods:

  • Lively small group discussions.
  • Quiz, Exercises & role-play
  • Games & case studies
course contents:


LEAN MANUFACTURING/PRACTICES: AN OVERVIEW:

  • What is Lean Manufacturing/Practices?
  • The Key Business Questions
  • Lean Operations: What are YOUR reasons?
  • How will Lean techniques benefit your organization?
  • Key Factors in Lean success.
  • LEAN objectives for the organization

LEAN IMPLEMENTATION

  • Assessment before implementing Lean.
  • LEAN Management Leadership: What implementation takes?
  • Preparing the Organization, Lean Operations, the People
  • Lean foundation disciplines

GEMBA KAIZEN

  • What is GEMBA KAIZEN?   GEMBA & Management
  • The ultimate goal of KAIZEN strategy
  • Standardization, 5S Good Housekeeping, MUDA elimination, POKA-YOKE.
  • The Golden Rules of Gemba Management
  • Application of the Golden Rules

5S: FIVE STEPS WORKPLACE ORGANIZATION & VISUAL MANAGEMENT

  • Maintain & improve standards
  • Implementation of 5S Good Housekeeping
  • What is Visual Management?
  • Making problem visible.
  • Visual Management in 5Ms:
     - Manpower (Operators)
     - Machines
     - Materials
     - Methods
     - Measurements
  • Visual Management with 5S

MUDA (or Wastes) ELIMINATION

  • Muda of Transport
  • Muda of Inventory
  • Muda of Motion
  • Muda of Waiting
  • Muda of Over-Processing
  • Muda of Over-Producing
  • Muda of Defects
  • Muda of Time
  • MUDA (wastes), MURA(variation) & MURI (overburden)

POKA-YOKE (Error-Proofing)

  • What is POKA-YOKE?
  • Strategies for Zero Defects?
  • 10 types of human mistakes
  • Principles for POKA-YOKE improvements
  • Making suggestions for POKA-YOKE

IMPLEMENTING KAIZEN

  • Management roles & accountability in implementing KAIZEN.
  • Teamwork & Total Employees Involvement (TEI)
  • Manager’s Roles to get People Involvements in small group activities:
     - SGA/QCC/ICC
     - Training & Empowerment
     - Employees Hall of Fame
who should attend:
  • Managers, Dept. Heads, Engineers, Executives, Supervisors and all levels of employees who are responsible for implementing LEAN and/or TQM practices in the organization.
 
administrative details :
Duration : 2 days
Time : 9.00am - 5.00pm
Venue : In-house or public program
Language medium : English
 
 
Trainer :
Nelson Kok (please click here to see trainer's profile)
 
 
 
 
 
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