KAIZEN Lean Practitioner

KAIZEN Lean Foundations (4 days)

Objectives
Participants will understand the origin, principles and philosophy of KAIZEN® Lean and Anti-waste awareness is rekindled through practical hands-on exercises in the workplace. Techniques are practiced to systematically identify and eliminate areas of waste.

Content

• Origin and development of KAIZEN® Lean
• KAIZEN® Lean philosophy (GEMBA, MUDA, etc.)
• Waste in the production and service area
• MUDA searching - live on-the-spot
• Presentation of potential improvement
• 5S campaign, benefits of standardization
• Deming circle (SDCA / PDCA)
• Structured problem solving
• 7 quality tools
• Success control through visual management
• Integration of staff in the KAIZEN® Lean process
• KAIZEN® Lean in the office/administrative area

TPM Basics / Foundations (4 days)

Objectives
Participants will understand the objectives and set-up of the TPM®-system (8 TPM® pillars). They will know the TPM® main losses and learn the methods of autonomous maintenance. They are able to participate in the introduction of TPM®. They know the KAIZEN® Lean methods for preventing production disruptions and they understand that sound recording of data is necessary for combating faults (visual management).

Content

• Introduction TPM
• Kobetsu KAIZEN® Lean process
• Systematic reduction of the 16 main losses
• Recording of the key figures of production (OEE)
• Target-oriented qualification of staff
• Autonomous maintenance
• Planned maintenance
• Audit system
• Recording of the key figures of maintenance (MTBF/MTTR)
• Measures for the optimization of maintenance efficiency

KAIZEN Lean Supply Chain Basics /TFM (4 days)

Objectives
Participants will understand the objectives and methods of Just-in-Time philosophy and are in a position to participate in the introduction of Lean Supply Chain/Flow principles. They are able to identify waste in production and systematically eliminate the underlying causes using KAIZEN Lean Flow tools. Thereby, they will make a crucial contribution to achieving a lean and flexible enterprise across the entire lean supply chain

Content

• Principles of Just-in-Time production
• Detecting waste through excessive production and stocks
• From batch production to assembly line production
• Adapting to customer cycle and One-Piece-Flow
• Types of line design (e.g. U-layout)
• Ergonomics at workplace
• Standardized work
• Supplying of lines
• Principles of the PULL system
• Principles of KanBan
• Supermarket principle
• Leveling and the reduction of set-up time (SMED)