Introduction to Process Improvement and LEAN
ProjectTraining.com
| Providing Project Management and Process Improvement Training for over 20 years |
2-day Workshop
This course outlines and provides hands-on practice with tools and techniques
for process improvement. The tools can be used to document either new or
current processes, identify areas of waste, redundancy, and inefficiency, gather
data for decision-making and process improvement activities, and to construct
the documentation needed to maintain the process. The workshop is highly
interactive with participants applying the tools and techniques to real-world
examples from their own work situations.
Introduction
The basic concepts of LEAN
The LEAN methodology is used to:
The overall approach to process improvement:
The four-phase approach:
Conclusion
This course outlines and provides hands-on practice with tools and techniques
for process improvement. The tools can be used to document either new or
current processes, identify areas of waste, redundancy, and inefficiency, gather
data for decision-making and process improvement activities, and to construct
the documentation needed to maintain the process. The workshop is highly
interactive with participants applying the tools and techniques to real-world
examples from their own work situations.
Introduction
- What processes are:
- Enterprise-wide processes
- Cross-functional processes
- Work processes
The basic concepts of LEAN
- Introduction
- 5S
- Basic ideas
- Pull processing
- Perfect first-time processing
- Waste minimalization
- Continuous improvement
- Flexibility
- Building and maintaining long term relationships
- Autonomation
- Load leveling
- Visual control
- The five core concepts:
- Specify value in the eyes of the customer
- Identify the value stream and eliminate waste
- Make value flow at the pull of the customer
- Involve and empower employees
- Continuously improve in the pursuit of perfection
- The original Seven Deadly Wastes
- Overproduction
- Transportation
- Waiting
- Inventory
- Motion
- Over processing
- Defects
- LEAN, the organization and its people
The LEAN methodology is used to:
- Streamline existing processes
- Design new processes
- Redesign existing processes
- Align business processes and organization with company goals
The overall approach to process improvement:
- Analyze the existing process
- Identify changes needed to meet business requirements
- Develop measurement systems to monitor the process
- Establish a means to provide forf on-going improvement
The four-phase approach:
- Scan:
- “Walk” the process
- Collect and document quantitative data and anecdotal information.
Document: - Process steps (the actual work)
- Process time (how long work takes, where delays occur, travel
time, etc.) - Work methods and tools
- Process inputs
- Process outputs
- Skills needed
- Additional information resources for each step
- Clarify and define required process outcomes
- Identify opportunities for improvement
- Plan:
- Establish the boundaries of the improvement effort
- Map the existing process
- Document waste, inefficiencies, delays, redundancies, etc.
- Design the improved process
- Plan the implementation, measurement system and on-going
improvement process
- Implement:
- Provide training if needed
- Provide job aids and other tools if needed
- Transition to the improved process
- Implement the measurement system
- Implement the on-going improvement process
- Monitor:
- Initial monitoring (of the implementation and first “runs” of the
process) - On-going monitoring
Conclusion
- Some things to watch for
- Notes for redesign teams
“Why spend all this
time finding, fixing and
fighting when you
could have prevented
the problem in the first
place?”
Philip Crosby
(1926 - 2001)
Businessman and
author
time finding, fixing and
fighting when you
could have prevented
the problem in the first
place?”
Philip Crosby
(1926 - 2001)
Businessman and
author
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