Lean is a management philosophy based on the Toyota Production System (TPS). With Lean Manufacturing, you will be able to enhance value for your customers by improving and smoothing the process flow and eliminating waste. Simply put, with Lean, you will be able to increase productivity and create greater customer value with less resources.

By teaching this presentation, managers and employees will have a better understanding of the Lean principles and approach to eliminating waste, and will be more forthcoming to lead and participate in the Lean implementation process.

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NOTE: This training package includes:
1. Lean Manufacturing training presentation (PowerPoint format)
2. Lean poster (PDF format, in color and monochrome, printable in A3 size)
3. Eight Wastes of Lean poster (PDF format, in color and monochrome, printable in A3 size)
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LEARNING OBJECTIVES

1. Understand the key concepts and principles of Lean
2. Acquire knowledge on the common Lean methods and tools and their applications to eliminate waste and create more value for customers
3. Identify ways to develop "Kaizen eyes" to look for improvement opportunities
4. Describe the various Lean roles
5. Define the critical success factors for sustaining a Lean culture

CONTENTS

1. Introduction to Lean Thinking
- The case for Lean Manufacturing
- Where did Lean originate?
- Toyota's philosophy
- Lean adoption in various environments
- Impact of Lean principles in industry
- Lean applications in manufacturing, process and service industries
- What is Lean?
- What Lean is not
- Traditional thinking versus Lean thinking
- Traditional culture vs. Lean culture
- Lean management framework
- Lean and six sigma
- Benefits of Lean manufacturing

2. Key Concepts of Lean Thinking
- Methods to increase productivity
- What is waste?
- Work versus waste
- Value defined
- Cost reduction principle
- 20 minutes of waste a day
- Eight types of manufacturing waste
- Examples of value-added activities
- Examples of waste
- Lean emphasis
- Lean thinking philosophy
- Lean principles

3. Common Lean Methods & Tools
- Muda, Mura & Muri
- Gemba framework
- 4Ms
- 5S principles
- Visual controls
- Plant layout
- Cellular layout
- Total Productive Maintenance
- Standard work
- Heijunka (Load leveling)
- Supermarket
- Kaizen
- Pull systems / Kanban
- Continuous Flow
- Takt time
- Quick changeover / Set-up reduction
- Fexible workforce
- Quality at source
- Poka yoke (error-proofing)
- Andon
- PDCA problem solving
- Small group activities
- Suggestion system
- Hoshin Kanri

4. Ways to develop "Kaizen Eyes"
- What are "Kaizen eyes"?
- Ways to develop "Kaizen eyes"

5. Lean Roles
- Lean steering committee
- Lean deployment leader
- Lean champions
- Lean process owner
- Lean coach
- Team leader
- Team members

6. Sustaining a Lean Culture
- Challenges in Lean manufacturing
- Understanding responses to change
- Sustaining a Lean culture
- Lessons from other adopters