Modules
01. Context and History
Lessons
- Why improve?
- Why continuous improvement?
- History of production – Pre Ford
- History of production – Ford and beyond
- History of Statistical Process Control – SPC
- History of Continuous Improvement
- History of Total Quality Management – TQM
- History of Lean
- History of Kaizen
- History of Total Productive Maintenance – TPM
- History of Six Sigma
- History of Lean Six Sigma
- History of Theory of Constraints – TOC
- History of Project Management
- History of Agile
- History of belts
02. The Absolute Basics
Lessons
03. Project Management
Lessons
04. Basic Define
Lessons
- Goal of Define
- Project Identification & Selection
- Stakeholders & Governance
- Voice of Customer, Business & Employee
- Problem Statement
- Business Case & Financial Justification
- Goal Statement & CTQ
- Process Scope & SIPOC
- Timeline, Milestones, Tollgates & Risks
- Creating the Project Charter
- Charter Approval & Team Formation
05. Basic Measure
Lessons
- Data collection
- Check sheets
- Work sheets
- Concentration diagrams
- Questionnaires
- Data visualization
- Scatter plot
- Pareto chart
- Bar chart
- Pie chart
- Time Series Plot
- Histogram
- Box plot
- Performance measurement |Quality
- PPM – Parts per Million
- DPMO -Defects Per Million Opportunities
- DPU – Defects per Unit
- RTY
- FTR – First Time Right
- Defect versus defective
- Performance measurement | Time & Throughput
- Takt time
- Cycle time
- Lead time
- OEE -Overall Equipment Effectiveness
- Little’s Law
06. Basic Analyze – Understand the Current Condition
Lessons
07. Basic Improve – Create the Target Condition
Lessons
- Understand the obstacle – The Gap
- Value added versus non-value added
- MUDA – Waste
- MURA – Fluctuation
- MURI – Overburden
- MUDA reduction
- MURA reduction
- MURI reduction
- Design the future
- Value Stream Mapping – Future State
- Continuous Flow
- Pull – JIT
- Kanban
- Heijunka – Level Scheduling
- Balanced Workload
- Review and discuss different layouts
- Standardized Work
- 5S
- Cycle-time reduction
- Single Minute Exchange of Dies – SMED
- Jidoka – Zero Defect Principle
- Autonomation
- Andon
- Poka-Yoke
- Process and Quality control
- Proof effectiveness
- Experimenting
- Proof of concepts
- Try-storming
- Simulations
- Pilot tests
08. Basic Control
Lessons
- Establishing and communicating the new standard
- Document control
- Control plan
- Response Plan
- Work standards and Standardized Work
- Training plans & Training Within Industry – TWI
- Professional work
- Visual Management
- Stand-up Meetings & Short Interval Control
- SQDC
- Keep the saw sharp
- Audits
- Quality Management
09. Philosophy
Lessons
- Philosophy as a lens
- Ford – American
- Fords challenge
- Fords Solution
- Scientific Management
- Assembly line mindset
- Toyota – Japanese
- Toyota’s Challenge
- TPS as a thinking system
- Genchi Genbutsu / Gemba
- Kaizen
- Womack & Jones – Anglo-Saxon
- Womack & Jones Challenge
- The machine that changed the world
- Lean Thinking
- Six Sigma – American
- Six Sigma’s Challenge
- Boardroom origins
- Data & statistics as authority
- Belts & governance
- Is this really what Motorola did?
- Agile – people-centered
- Agile’s Challenge
- Agile Values and Principles
- Iterative learning
- Toyota Way 2001
- Toyota Way 2001 Challenge
- 2 Pillars
- 5 Keywords
- Liker 2004
- Liker 2004 Challenge
- 4P Model 2004
- 14 Principles of Liker
- Liker 2021
- Liker 2021 Challenge
- Influence of Toyota Kata by Mike Rother
- 4P Model 2021
- 14 Principles of Liker 2021
10. Strategy & Organization
Lessons
- WHY?
- True North
- Vision
- Mission
- Business drivers
- Organizational drivers & metrics
- Financial & performance metrics
- KPIs
- COPQ
- WHAT?
- Wardley
- Policy Development
- Policy Deployment
- Project Selection
- Project goals
- Breakthrough projects
- Daily improvement in operations
- Portfolio prioritization
- HOW?
- Improvement alongside the hierarchy
- Six Sigma roles & responsibilities
- Building a Six Sigma team
- Kaizen Event/Blitz
- Improvement within the hierarchy
- Learning Organization
- Continuous Improvement
11. Collaboration & Change
Lessons
- The Psychology of Change
- Kotter
- Covey
- Meaningful goals
- Psychological safety
- Individual and team empowerment
- Team Formation and Roles
- Team selection
- Team roles and responsibilities
- RACI
- Project Ground Rules
- Team stages
- Communication and Decision-Making
- Communication techniques
- Team communication
- Brainstorming
- Decision-making techniques
- Reaching consensus
- Group Dynamics and Pitfalls
- Negative dynamics
- Groupthink and feuding
- Meeting pitfalls
- Opinions vs. Facts
- Coaching and Development
- The importance of coaching
- Coaching techniques
- Intervision