Lean Office training

1st Day

LEAN PHILOSOPHY

- Basics of Lean thinking
- Value-added conception
- Lean principles (5 principles)

LEAN OFFICE PRINCIPLES

- Customer focus, internal customer – supplier relations
- Value Stream
- Continuous material and information flow
- Pull system, JIT
- Flexible organizational solutions
- Kaizen, problem solving
- Work balancing
- Synchronized processes

KAIZEN PHILOSOPHY AND APPROACH

- Connection of KAIZEN and Lean
- Features of KAIZEN
- 4 principles of KAIZEN
- Examples of KAIZEN implementation
SIMULATION GAME– Lean versus Traditional operation

2nd Day

GEMBA KAIZEN

- 5 GEN, Gemba Kaizen approach
- PDCA – SDCA cycle
- Maintenance and  continuous improvement
- Based on facts leadership
- Measurement, data collection
- Determine targets and requirements

STANDARDS

- Function of standards
- Steps of standardization
- Elements of standardized work
- 5S METHOD
- 5S steps, introduction

VISUAL MANAGEMENT

- Transparency, visualisation
- Information structures, control
- Examples of visual management
- INVOLVING EMPLOYEES
- Employee int he focus principle
- Catapult game – PDCA

3rd Day

KAIZEN – PROBLEM SOLVING

- Problem solving in 7 steps, Kaizen steps

PROBLEM EXPLORATION’S TOOLS

- Defining problem (Tregoe)
- Identify KAIZEN possibilities

PQCDSM check list

- 4M method
- 5W 1H method
- 3 MU method
- 5 WHY method
- Task: KAIZEN practice

FURTHER ANALYSIS TOOLS:

- Flow charts, Value Stream Mapping 
- Performance measurement, Benchmarking
- 5W 1H method
- Spaghetti diagram, cycle time diagram
- Standard work combination sheet
- 7 MUDA – LOSS REDUCTION
- Office losses, information losses

4th Day

PROBLEM SOLVING

- Tools of problem solving
- 7 QC tools
- Before KAIZEN, after KAIZEN
- Kaizen diary, action plan

PROBLEM SOLVING IN TEAM

- Brain storming, Affinity diagram
- Check list in 7 steps

0 DEFECT CONCEPTION

- FMEA, good quality first
- JIDOKA, POKA-YOKE
- KAIZEN Story Board
- Presentation of the KAIZEN results

5th Day

KAIZEN SYSTEM

- Kaizen actions, Kaizen sheets
- Kaizen organization, Kaizen levels
- Role and duties of the KAIZEN manager
- Involving people into KAIZEN activity, motivation
- Improve an incentive system to support Kaizen
- Improve an organizational structure to support Lean implementation

SUGGESTION SYSTEM

- Praparation and planning of trainings
- Elements of effective training
- Training during work
- One-point lessons
- Evaluating training

KAIZEN IN PRODUCT IMPROVEMENT

- QFD, quality planning
- LEAN OFFICE
- KAIZEN in the office
- Loss reduction in administration area
- Office 5S, aspects and scheduling of 5S method implementation in office area
- Time management, effective elecronical communication
- 0 defect conception, defect free processes, process improvement
- Lean implementation effects on the work of non-productive areas
- Office Kaizen
- Case Study

PILOT PROJECT

KAIZEN activity implemented at the participant’s workplace

EXAM