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Course Overview

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The 5-day course comprises of two parts: Foundation and Practitioner.

 

The Foundation part covers:

• The topics who will prepare the delegates to attend the Practitioner part

• The philosophy, concepts, tools and techniques related to continuous process and business improvement.

 

This part of the course prepares delegates with the knowledge required to:

• Participate as Solution team members in a Kaizen Event

• Confidently meet the requirements of business and process stakeholders, including internal customers.

 

The Kaizen Foundation provide insight into the fundamentals of applying the Lean Thinking philosophy, principles, tools and techniques in the workplace to improve the business.

 

​The Practitioner part:

• Builds on the knowledge acquired at the Foundation training

• Aims to provide a more detailed explanation of how Lean principles, concepts, tools, and techniques

• Can be applied in a workshop environment, such as during formal Kaizen Event.

 

Such events may last between 2 and 5 days, depending on the scope and objectives set by the management.

 

This part of training:

• Is useful for the Solution Team Members, especially the Team Leader

• Focuses primarily on the role of the Kaizen Facilitator/ Practitioner

• Prepare those assigned to this role to coordinate and effectively manage all stages of a formal Kaizen Event.

 

Delegates will become familiar with the objectives, deliverables, tools and techniques as they apply through the stages of the end-to-end of formal Kaizen Event, including:

• Ppreparation

• Pre-Kaizen

• Implementation

• Post-Kaizen.

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Who should attend

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This training course is designed for those professionals wishing to enhance their knowledge about the Kaizen philosophy, methodology, tools, and techniques.

 

It is suitable for those assigned to job roles such as:

• Kaizen Event Facilitator/ Team Leader

• Quality manager

• Production Engineer

• Department Manager

• Team Supervisor

• Process Owner

• Business Improvement Manager and Teams

• Lean and Lean Six Sigma Practitioner.

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Learning objectives

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After successful course completion, participants will be able to:

• Effectively plan, lead, and manage successful Lean Kaizen Events.

• Independently manage Continuous Improvement teams.

• Demonstrate knowledge, understanding, and application of advanced Kaizen tools and techniques

• Actively support a culture of continuous improvement.

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Course Modules

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Module 1: Introduction

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• History and background of Kaizen

• PDCA cycle and and the continuous improvement stages of the Kaizen cycle

• The types and purpose of Kaizen

• Kaizen vs. other problem-solving/ improvement methodologies

• Roles and responsibilities in formal Kaizen Events.

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Module 2: Kaizen Leader Training

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• Leadership and Change Management

• The role of Kaizen Facilitator/ Leader

• Short-term/ informal, vs. formal Kaizen Events

• Kaizen Roadmap

• Guidelines for effective Kaizen Events

• Overview of Kaizen Event tools, techniques, and control documents

 

Module 3: Kaizen Event Principles, Tools and techniques

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• Lean Concepts: customer, value, and waste

• Problem statement

• Kaizen Event goals and objectives

• Identifying Customer Requirement/ CTQs

• Stakeholder analysis and management

• Cost of Poor Quality CoPQ)

• Key Performance Indicators (KPIs)

• Lean waste (muda, muri, and mura)

• Error/ mistake Proofing

• Visual Management

• Spaghetti Diagram

• 5S

• Root Cause Analysis tools (5 WHYs, fishbone diagram)

• Problem Solving

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Module 4: Process and Value Stream Mapping

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• Overview

• Process mapping and analysis

• Value Stream Mapping and analysis

• Mapping Tools and Symbols

• Process Mapping and Value Stream Mapping of the Current State

• Process Mapping and Value Stream Mapping of the Future State

• Using Process Maps

• Value Stream Maps

• Prioritising and Selecting Kaizen Projects

• Identify Project, Champion, Project Owner

• Develop Project Charter and Project Plan

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Module 5: Stages, activities, and tools of formal Kaizen Events

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Preparation: Kaizen Event preparation and planning

 

• Phase 1: preparation

 

• Phase 2: pre-Kaizen meeting/ workshop/ planning

  • Welcome & introductions

  • Set-up expectations, scope and objectives

  • Provide focused training

  • Hand-over artefacts from preparation phase to the Solution Team

  • Prepare Kaizen Charter

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Course Agenda

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Day 1: Orientation

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• Kick-off meeting

• Document current state (AS-IS)

  • Process and/ or value stream mapping

• Analyse current state (AS-IS)

  • Value stream analysis

  • Identify Lean waste/ opportunities for improvement

  • Data collection

• Management briefing

• Set objectives for day 2

 

Day 2: Understand the current state (AS-IS)

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• Daily stand-up meeting of Solution Team

• Perform root cause analysis & identify the root causes creating waste

• Brainstorm to find solutions for eliminating the above root causes

• Group and prioritise solutions

• Design the future (improved) state (TO-BE or SHOULD-BE)

• Management briefing

• Set objectives for day 3

 

Day 3: Develop future state (TO-BE) process design

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• Daily stand-up meeting of Solution Team

• Review/ finalise the future (improved) state design(TO-BE)

• Assess risk, pilot, and implement the prioritised solutions

• Test or simulate the improved process

• Train people in the new process

• Fine-tune TO-BE process based on lessons learned

• Management briefing

• Set objectives for day 4

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Day 4: Pilot and implement selected solutions/ changes

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• Daily stand-up meeting of Solution Team

• Fine-tune TO-BE process based on lessons learned

• Complete risk assessment, piloting, and implementation of prioritised solutions

• Test or simulate the improved process

• Train people in the new process

• Standardise the improved process and update process documentation

• Measure improved process state performance

• Estimate/ calculate benefits

• Management briefing

• Set objectives for day 5

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Day 5: Finalise, report & celebrate

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• Daily stand-up meeting of Solution Team

• Finalise the improved process state

• Complete training and standardisation

• Final presentation to management team.

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Post-Kaizen

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• Monitoring and control of the new process

• Complete/ finalise any activities not completed during the event

• Kaizen Event Team meeting for final briefing and scheduling of next Kaizen Event

 

Prerequisites

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

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There are no formal prerequisites for attending this course - is open to individuals aiming to enhance their knowledge in Kaizen, and the way it is practiced in the context of Kaizen Events.

 

Training Approach

 

The course Agenda follows the 5-day schedule of a formal Kaizen Event, in the same sequence and fashion that the day-to-day activities take place in the context of the actual event.

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The course covers both theory and practice:

• Slide-based training sessions, illustrated with examples

• Business cases

• Preparation for the exam

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

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Examination and Certification

 

Certification Exam

 

• Duration       90 min.

• Format         Closed book

• Questions     60 multiple-choice questions

• Pass mark    70% (42 correct answers)

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Certification

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Candidates passing the exam will be awarded the Kaizen Practitioner certificate.

 

​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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For more details about our:

• List of training courses please click here.

• Consulting services please click here

• Workshops please click here.

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For queries, including non-obligation quotes, please contact us.

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