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- Introduction to the course structure, content, and navigation.
- Instructions for support and asking questions.
- Discover three perspectives to describe what lean is all about.
- Understand the role of scientific thinking in the origins and practice of lean.
- Learn four tips to help set you up for success learning lean.
- Understand a simple version of the "lean house," for the sake of organizing what you lean about lean.
- Learn how to define and identify "value" and "waste."
- Discover the three M's: muri, mura, and muda.
- Survey each of the 7 wastes of lean.
- Realize how lean methods approach cost reduction differently than conventional approaches.
- Learn the "Four Ms" of stability: man, machine, material, and method.
- Discover common factors that create instability in each category.
- Realize how stability is a prerequisite to standardization and continuous improvement.
- Define "standard work" and discover how it is much more than SOPs.
- Learn the many ingredients that are composed into a standard work "recipe."
- Overview four common types of standard work: 8-step-process, classic standardized work, TWI Job Instruction, and video.
- Discover four reasons why standard work is critical to your success.
- Learn the two primary purposes of 5S.
- Overview each of the five disciplines of 5S: sort, set in order, shine, standardize, and sustain.
- Discover the big picture as to why 5S matters.
- Define kaizen (continuous improvement) and discover its origins.
- Appreciate how kaizen is both a culture creating of small improvements, and also big improvements.
- Discover how 80% of your potential depends on kaizen by front-line associates.
- Overview how to run larger kaizen as an event.
- Discover what heijunka (production leveling) is all about.
- Learn why production leveling matters to the stability and efficiency of your organization.
- Understand production leveling conceptually via a scheduling example, and the role of schedule mixing and pattern production.
- Understand visual management through strong 5S controls, and also "expected vs. actual" performance.
- Survey common visual control boards: production tracking (hour-over-hour) chart, monthly tracking chart, job-by-job tracking chart, and a task completion board.
- Realize how these simple controls are essential to the success of lean management and PDCA/scientific thinking.
- Define "flow" and the concept of "just-in-time" (JIT) manufacturing.
- Explore the consequences of batch size as it relates to lead time and performance metrics.
- Learn how continuous flow produces better quality, reduced inventory, and faster feedback.
- Survey how to create balanced workcells with flexible manpower and one-piece flow.
- Define takt time and understand how it limits over production, creating steady flow.
- Learn how takt time limits overburden and unneveness.
- Learn how to calculate takt time based on customer demand.
- Define a pull system along with the term "kanban."
- Survey common pull systems including: one-piece-flow, FIFO, kanban supermarket, 1-card kanban, and 2 bin kanban systems.
- Compare and contrast the movement of material in push vs. pull systems.
- Understand what SMED is and why quick changeovers and critical to achieving leveled production and steady flow.
- Learn a simple 5-step approach to achieving shorter changeover times.
- Discover the importance of moving internal activities to external activities.
- Define a "value stream" and overview value stream mapping as a tool for continuous improvement.
- See an example of VSM in terms of a current state and future state map.
- Define "jidoka" and learn how to create smart automation with quality built-in.
- Understand key jidoka concepts including: a culture of "stop and fix problems," built-in quality, separation of man & machine, poka yoke, and andon.
- Learn the value of multi-process handling,
- Learn the two types of problems.
- Overview characteristics of effective problem-solving.
- Learn to connect problem-solving to the bigger picture with measurable impact.
- Survey common problem-solving tools: graphs/charts, fishbone diagrams, check sheets, control charts, histograms, and pareto charts.
- Understand the role of PDCA in effective problem-solving.
- Discover the critical ways in which lean management differs from traditional management.
- Learn the three lean management practices to create a lean culture.
- Overview how lean management is often structured vs. traditional organizational structures.
- Realize the important role of the team leader.