Lean Operations and Process Improvement for Executives

Duration: 7 Days
Target Audience: Senior executives, operations managers, process improvement leaders
Certificate: Certificate of Completion in Lean Operations and Process Improvement
Format: Hybrid (Online/In-Person)

Day 1: Introduction to Lean Principles and Operational Efficiency

• Objective: Understand the fundamentals of lean operations, focusing on waste reduction and efficiency in business processes.

Topics:

• Overview of Lean Principles and the Five Lean Concepts

• The Value Stream: Identifying Value from the Customer’s Perspective

• Understanding Operational Efficiency and Process Waste

• Interactive Session: Mapping value within participants’ processes

Learning Activities:

• Lecture: Introduction to lean thinking and operational efficiency

• Case Study: Companies that achieved success through lean practices

• Workshop: Participants identify value-adding and non-value-adding steps within a sample process

Day 2: Identifying and Eliminating Waste

• Objective: Learn to identify and eliminate waste using the “Seven Wastes” model to improve operational effectiveness.

Topics:

• The Seven Wastes (TIMWOOD): Transport, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects

• Tools for Waste Identification and Analysis

• Techniques for Waste Reduction

• Interactive Session: Analyzing a process to identify areas of waste

Learning Activities:

• Lecture: Techniques for waste identification and reduction

• Case Study: Examples of organizations that eliminated waste to drive performance

• Workshop: Participants map waste within a process and develop a reduction plan

Day 3: Lean Tools and Techniques for Process Improvement

• Objective: Discover key lean tools and methods for implementing process improvements.

Topics:

• Value Stream Mapping (VSM)

• The 5S System (Sort, Set in Order, Shine, Standardize, Sustain)

• Kaizen (Continuous Improvement) and Kaizen Events

• Interactive Session: Developing a VSM for a selected process

Learning Activities:

• Lecture: Introduction to VSM, 5S, and Kaizen as tools for lean improvement

• Case Study: Companies that used lean tools for significant process improvements

• Workshop: Participants create a value stream map and propose improvement actions for their organizations

Day 4: Process Mapping and Analysis

• Objective: Gain insights into process mapping techniques to analyze current workflows and identify improvement opportunities.

Topics:

• Creating Process Maps and Flowcharts

• Analyzing Bottlenecks and Inefficiencies

• Using Process Maps to Drive Decision-Making

• Interactive Session: Building a process map and conducting a bottleneck analysis

Learning Activities:

• Lecture: Importance of process mapping and analysis for lean initiatives

• Case Study: Organizations that optimized operations through process mapping

• Workshop: Participants map a process within their organizations and analyze bottlenecks

Day 5: Implementing Lean Improvements and Monitoring Results

• Objective: Learn the steps for implementing lean improvements and monitoring their effectiveness over time.

Topics:

• Creating an Implementation Plan for Lean Initiatives

• Key Performance Indicators (KPIs) for Lean Monitoring

• The PDCA (Plan-Do-Check-Act) Cycle for Continuous Improvement

• Interactive Session: Developing a lean implementation plan for a selected initiative

Learning Activities:

• Lecture: Strategies for implementing and sustaining lean improvements

• Case Study: Examples of organizations that successfully implemented lean changes

• Workshop: Participants create an implementation and monitoring plan for a process improvement project

Day 6: Lean Leadership and Change Management

• Objective: Explore the role of leadership in lean transformations and learn change management principles for successful lean adoption.

Topics:

• The Role of Leaders in Driving Lean Culture

• Change Management Techniques for Lean Success

• Engaging Teams and Sustaining Momentum

• Interactive Session: Designing a leadership plan for lean adoption

Learning Activities:

• Lecture: Key principles of lean leadership and change management

• Case Study: Examples of lean leaders who effectively transformed their organizations

• Workshop: Participants design a plan to lead and sustain lean practices in their organizations

Day 7: Capstone Project: Crafting a Lean Operations Strategy

• Objective: Apply course learnings to develop a comprehensive lean operations strategy tailored to participants’ organizations.

Topics:

• Integrating Lean Principles into Organizational Strategy

• Presenting Lean Strategy Plans

• Peer Review and Feedback

• Certificate Ceremony and Reflections

Learning Activities:

• Capstone Project: Participants develop and present a lean operations strategy for their organization

• Peer Review: Teams provide feedback on each other’s strategies

• Certificate Ceremony: Award certificates of completion

Key Features of the Course:

• Expert Faculty: Taught by lean experts, operations consultants, and senior executives with experience in lean transformations.

• Interactive Learning: Includes workshops, case studies, and group exercises to reinforce lean tools and techniques.

• Capstone Project: Participants leave with a lean operations strategy, equipped to drive efficiency and improvement within their organizations.

• Certification: Recognized certificate of completion, demonstrating expertise in lean operations and process improvement.

Outcome:

Participants will acquire skills to lead lean transformations, enhance operational efficiency, and build a sustainable culture of continuous improvement within their organizations.