ISO 18404 Six Sigma & Lean Implementation - Lean Practitioner

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Introduction

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Lean Thinking is a term used to describe the process of making business decisions in a Lean way. It is regarded as the foundation of any Lean practice, such as: Lean manufacturing, Lean Services, Lean IT, Transactional Lean, Lean Healthcare, Lean Accounting, Lean Start-up, etc.

 

Lean Thinking is:

• Business improvement methodology aiming to provide a new way of thinking about how to organize human activities to deliver more benefits to society and value to individuals while identifying and eliminating waste.

• A  term that was coined by James P. Womack and Daniel T. Jones to capture the essence of their in-depth study of Toyota's Production System (TPS).

• A way of thinking about an activity and seeing the waste inadvertently generated by the way the process is organized.

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The aim of Lean Thinking is to create a Lean Enterprise, i.e. an organisation that:

• Grows in a sustainable way by linking and satisfying the four interrelated "voices", i.e. VOC, VOE, VOP, and VOB associated with needs and requirements of the following:

  • Business customers (Voice of the Customer) - product or service quality, cost (price), and delivery (QCD)

  • Employees (Voice of the Employee) - salary, benefits, professional development, and career progression opportunities

  • Business processes (Voice of the Process) - performance of core, management, and supporting business processes

  • Business (Voice of the Business)- sustainable and profitable business growth, sales, revenues, compliance, etc.

• Aims to deliver defect-free and fairly priced products or services profitably

• Strives to identify and eliminate "waste" (muda) from its processes, products or services, without sacrificing quality, while minimizing unnecessary overheads to the business and costs related to customers, suppliers and the environment.

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Overview

 

This 3-day interactive and highly practical course will provide first-hand experience of the approaches and tools of Lean that are used to affect continual improvement which is:

• Strategic business goal for most organizations

• Requirement in standards such as ISO 9001, ISO 13053, and ISO 18404.

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Lean methods provide a simple and effective approach to identifying and removing waste in processes, thereby improving the following:

• Process execution speed (Lead Time),and flow of materials, information, and value

• Efficiency and effectiveness of day-to-day operational activities.

 

Who should attend

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This course is designed for:

• Lean and Six Sigma Practitioners who wants to apply effective and structured Lean continual improvement techniques and methodologies to help their organization make step change improvements in quality and efficiency

• Those individuals who aspire to become certified to the ISO 18404 standard by meeting the relevant requirements of the standard

• Senior Managers and Quality Management Professionals in organisations aspiring to be certified to the ISO 18404 standard.

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Learning objectives

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On completion of the course delegates will be able to:

• Describe the Lean principles, tools and techniques of continual improvement

• Select and apply the correct tools and techniques within the operating business environment to:

• Eliminate or minimise non-value adding process tasks and activities type I and type II waste)

• Reduce the end-to-end process Lead Time

• Contribute to value creation, in the form of products or services, and delivery to business customers

• Use the principles of total productive maintenance (TPM), and other Lean tools and techniques such as the Lean Triad (5S, Poka Yoke, and SMED) to reduce machine and system downtime and enhance process performance

• Demonstrate to the organization that Lean tools and techniques can be applied to improve employee engagement and productivity and  continual process and business improvement

• Use Lean measures and metrics, such as Lead Time, Cycle Time, Unit Time, Takt Time,  OEE (Overall Equipment Effectiveness), TEPP (Total Effective Equipment Performance) to quantify process performance improvements

• Use the Kaizen approach to implement "quick wins", using Lean tools and techniques

• Relate effective Lean continual improvement activities to the management of organizational quality and efficiency.

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Course Agenda and Content

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Day 1

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• Introductions and course administration

• Learning objectives

• Course structure - Overview

• Lean basics: philosophy (Lean Thinking), principles, and Lean Temple

• Overview of Lean tools and techniques

• Customers, value and waste

• 3 Ms of Lean (muda, mura, and muri)

• 8 forms of Lean waste (muda)/ NVA)

• SIPOC diagram, process and value stream mapping and analysis

• Lean metrics and measures

• Production levelling/ smoothing (heijunka)

• Process levelling techniques

• Process design basics

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Day 2

 

• Push vs. pull systems, Kanban

• Error/ mistake-proofing to enhance product and service quality

• Visual management system

• Process control plans

• Total Productive Maintenance (TPM)

• 5S for workplace organization

• Single Minute Exchange of Dies (SMED)

• Lean Enterprise

• Daily Kaizen

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Day 3

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• Day In the Life Of (DILO) analysis

• Business problem-solving frameworks

• Formal Kaizen events vs, Kaizen Blitz

• Lean management

• Lean teams

• PDCA for continual improvement

• Lean start-up

• Enterprise 4.0

• Services 4.0

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Prerequisites

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• Proficiency in the English language, willingness to learn, and open mind to new ways of working.

• Understanding the basics of Six Sigma, Lean, and Lean Six Sigma at (minimum) Yellow belt level is recommended

• Any knowledge related to the ISO 13053 standard (Parts 1 and 2) will be highly beneficial.

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Training Approach

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The course covers both theory and practice:

• Slide-based training sessions, illustrated with examples

• Business cases

• Preparation for the Lean Practitioner exam

• Practice test (mock exam) similar to the certification exam.

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Examination

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• Duration        90 min.

• Format          Closed book

• Questions     60 multiple-choice questions

• Pass mark    70% (min. 42 correct answers)

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Certification

 

The ISO 18404 Lean Practitioner certificate will be issued to delegates passing the exam.

 

General Course Information

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For general course information please click on the link here.

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N.B. Please read our Terms & Conditions (T&Cs) and ask for clarifications, if any, before booking your training event.

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Book now to reserve an on-site or online instructor-led training event of your choice.

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