To equip participants with practical lean tools vis-à-vis efficiency and productivity improvement in business operations. In today’s highly competitive environment, being a lean organisation has become extremely important. This seminar helps provide course participants with the strategic knowledge and skills to apply lean principles in business organisations. Participants will gain an overview of the Toyota Production System and the origins and principles of lean methodology and will develop a working knowledge of its supporting tools and techniques. The seminar covers the five stages to lean, waste-free operations, including the application of mapping and continuous improvement tools, and offers an opportunity to work as a team with fellow participants and implement lean principles in a realistic operations simulation and Kaizen event regarding value enhancement, lean startup methodology, practical method for lean pillar deployment in contemporary manufacturing and service-oriented organisations. In today’s complex business environment, characterised by pervasive economic uncertainty, increasing customer expectations, and intensifying competition, organisations are constantly seeking to develop and execute a winning strategy especially on cost reduction and continuous improvement as per quality product and service delivery.
The lean methodology encourages continuous improvement, which is a long-term process where small changes are implemented systematically. These changes to processes are incremental and increase quality and efficiency. The term Lean Management refers to an end to end business process and system for organising and managing product development, manufacturing, operations, service, suppliers, customer relations, and the overall enterprise. Lean applies in every business and process. It is not a cost reduction program, but an approach to optimise end to end processes towards having maximum value for everybody through the systemic identification and elimination of losses.
This intensive 3-week seminar begins with an exploration of lean principle, methodology, tools, types, and categorisation of wastes via loss stream, lessons from the Toyota production system (TPS), concepts of efficiency and productivity, and case discussion. The second week will focus on Lean Archetype, lean supply chain (Lean in the value-adding stream), lean-based accounting, and practical sessions of lean implementation in manufacturing and service organisations. The third will address lean Architecture, lean deployment, lean implementation, Process Kaizen Event (PKE), lean maturity, and ethical aspects of lean thinking. Participants will learn how to close challenges of operational under performance via losses in the value stream, acquire the skills of diagnosing process toward identification of gaps, people capability building regarding operation systems, management infrastructure, mindset, and behavioral mapping of organisational employees. Also, take-away will include practical ability to implement lean and sustaining a lean culture in both manufacturing and service organisations.
Fundamentals of Lean Thinking and Methodology
- Introduction and Overview of Seminar
- Concepts of Efficiency and Productivity Improvement (Paradigm Shift)
- Lean Methodology and Principles
- Lean Tools ( e.g. Gemba, 5s, Visual management, PDCA)
- Root-causes and types of Wastes / Losses in manufacturing and service organisations
- Value Stream Mapping and Throughput maximisation via lean approach
- Case / discussion
Lean Archetype: Office, Service, and Manufacturing
- Lean in Manufacturing organisations
- Lean in Service Organisations
- Lean in Office and IT
- Lean Metrics
- Lean Supply Chain: Value Chain Lean implementation
- Lean-based Accounting fundamentals and application
- Practical Industrial lean game / experience ( Industry experience / expertise)
- Lean Architecture: Operating System, Mindset & Behavioral Capabilities, and Management Infrastructure
- Practical lean Deployment: Operational Pillar Approach for Manufacturing and Service organisations
- Lean implementation pillars: Standard Daily Work (SDW), Plan Maintenance, Safety, Health, & Environment (SHE), Focused Improvement, Training & Development, Early Management, Quality.
- Process Kaizen Event ( PKE) and class exercise
- Lean Maturity and Continuous Improvement
- Video on lean application
- Ethical Aspects of a Lean enterprise : Business, People, and Environmental implications
Key Learning Outcomes
- Utilise lean tools in driving efficiency and productivity towards the elimination of key losses and waste in the operational value stream.
- Learn to match employee mindset and behaviour to a productive and efficient operating system in eliciting “waste-free” operations.
- Appraise business needs, improvement potential, change capability, and ‘know-how’ for the success and sustenance of a lean system in an ethical manner.