Course Outline

Kaizen Foundation Training

Kaizen Overview

• Concepts and Principles of Kaizen
• Kaizen Application Insight
• Crucial Implementation Issues and Strategies
• Maintaining Kaizen Implementation

Kaizen Strategy

• Role of Management
• Planning a Kaizen Continuous Improvement Programme
• Change Management
• Tailoring the Culture to Kaizen
• Kaizen Tools
• Selecting and Handling Projects
• Identifying Teams to Implement Kaizen
• The Roles of Team Members
• Performance Metrics
• Successful Kaizen Implementation

Kaizen Tools

• Kaizen Quality Improvement Tools
• 7QC Tools and their Application
• Check Sheet
• Pareto Chart
• Histogram
• Scatter Diagram
• Process Map
• Cause and Effect Diagram
• Process Map
• Control Chart

The Kaizen Week Approach

• Kaizen Week Preparation
• General Kaizen Week Framework
• Facilitation Keys
• Kaizen Team Rules
• Kaizen Week Schedule
• 7 Types of Waste
• Overproduction
• Overprocessing
• Waiting
• Motion
• Transportation
• Inventory
• Rework

Kaizen Advanced Concepts

• Kaizen Tools and Techniques
• Change Management
• Leadership
• Tailoring Culture
• Aligning Improvement Programs to Business Objectives
• Introduction to Value Street Mapping
• Selecting and Managing Projects
• Developing a Kaizen Roadmap
• Role of the Kaizen Leader
• Planning and Organising Effective Kaizen Events

Kaizen Practitioner Training

Kaizen Introduction

• History of Kaizen
• Kaizen Comparison with Other Improvement Methodologies
• Kaizen Roles and Responsibilities 

Kaizen PDCA (Plan, Do, Check, and Act)

• Plan Phase
• Event Planning
• Event Charter
• Event Data Collection
• Event Data Display
• Do Phase
• Process Mapping
• Lean Efficiency Metrics
• Process Value Analysis
• Root-Cause Analysis
• Error Proofing
• 5S and 8 Wastes
• Solution Selection
• Check and Act Phase
• Monitoring and Controlling the New Process
• Standards Development
• Solution Replication Opportunities Identification

Kaizen Leader Training

• Leadership and Change Management
• Role of Kaizen Leaders
• Relationship between Long-Term Kaizen Projects and Intensive Kaizen Events
• Develop the Kaizen Roadmap
• Projects Framework/Effective Kaizen Events
• Kaizen Tools and Forms

Kaizen Concepts and Tools

• Kaizen Concepts
• Define Quality, Problem
• Understand the Objectives of Kaizen
• Identify Customer Requirements
• CTQ Matrix
• Resource/Stakeholder Analysis
• Cost of Quality
• Voice of Customer
• Identify Key Performance Indicators (KPIs)
• Waste Identification and Elimination
• Mistake Proofing
• Visual Management
• Spaghetti Diagram
• Continuous Flow
• 5S
• Root Cause Analysis
• Team-Based Problem Solving
• Project Charter

Mapping of Process and Value Stream

• Overview of Process Mapping
• Value Stream Mapping Principles and Methodology
• Mapping Tools and Symbols
• Process Mapping and Value Stream Mapping of the Current State and Future State
• Using Process Maps
• Value Stream Maps
• Prioritising and Selecting Kaizen Projects
• Identify Project, Champion, and Project Owner
• Develop Project Charter and Project Plan

Kaizen Project Implementation

• Identify the Kaizen Project
• Establish the Project Structure
• Prepare the Kaizen Event
• Map Current State for the Kaizen Project
• Identify Areas for Improvement
• Map Future State
• Cost and Benefit Analysis of Projects
• Implementing Future State Improvements
• Post-Project Review and Follow-Up
• Identify Further Areas for Improvement/Skills Development
• Project Presentation