LEAN Concept in Reduction of Waste in the Organisation
This course provides a proven methodology for Lean Management, focusing on eliminating waste, optimising processes, and improving continuous flow. It streamlines operations and creates value by minimising waste across various industries.
Programme Overview
In today’s fast-paced business environment, organizations are constantly striving to improve efficiency, reduce costs, and deliver high-quality products and services. Lean Management provides a proven methodology that helps businesses achieve these goals by focusing on eliminating waste, optimizing processes, and improving continuous flow.
Lean is a management philosophy and set of principles designed to streamline operations and create value for customers by minimizing waste. Originating from the Toyota Production System (TPS), Lean has become widely applicable across industries, from manufacturing to healthcare and even service-based sectors.
Learning Outcomes
Introduction to Lean Principles
Value Stream Mapping (VSM)
Waste Identification (Muda)
Root Cause Analysis (RCA)
Lean Tools and Techniques
Leadership in Lean
Who Should Attend?
Everyone in the organization dealing with process, resources, and cost management.
Employees, including management, seeking a well-rounded foundation in Lean Management.
Individuals aiming to apply Lean knowledge to reduce waste in their day-to-day operations.
Those looking to optimize their cost of operation.
Course Outline
Day 1 (9:00 AM to 5:00 PM)
Module 1: Introduction to Lean Principles
- Overview of Lean Management
- Understanding its origins (Toyota Production System, Taiichi Ohno) and core philosophy
- The 5 Lean Principles: Value, Value Stream, Flow, Pull, and Perfection
- Benefits of Lean: Improving quality, reducing costs, enhancing customer satisfaction, and streamlining operations
Module 2: Value Stream Mapping (VSM)
- Purpose and benefits of value stream mapping
- How to map value streams
- Identifying value-adding and non-value-adding steps in processes
- Creating a current state and future state map
Module 3: Waste Identification (Muda)
- What is Waste?
- 7 Types of Waste (TIMWOOD): Transport, Inventory, Motion, Waiting, Overproduction, Overprocessing, and Defects
- How to identify waste in various processes
- Strategies to reduce or eliminate waste
Day 2 (9:00 AM to 4:50 PM)
Module 4: Root Cause Analysis (RCA)
- Techniques for identifying the root causes of problems
- “5 Whys” Tools
- Fishbone Diagrams (Ishikawa)
- Developing corrective actions based on the root cause
Module 5: Lean Tools and Techniques
- Poka-Yoke (Error-Proofing): Preventing mistakes before they happen
- Takt Time: The rate at which products must be produced to meet customer demand
- SMED (Single-Minute Exchange of Dies): Reducing setup times in manufacturing
- Heijunka (Level Scheduling): Balancing production to smooth out workloads
Module 6: Leadership in Lean
- Change Management
- Role of leadership in implementing Lean
- Implementing a Lean culture
- Managing change and overcoming resistance to Lean transformation