Certified Kaizen Foundation & Practitioner - Papua New Guinea

Certified Kaizen Foundation & Practitioner Course Outline

Module 1: Kaizen Overview

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

Module 2: Kaizen Strategy

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

Module 3: Kaizen Tools

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

Module 4: Kaizen Week Approach

• Kaizen Week Preparation
• General Kaizen Week Framework
• Facilitation Keys
• Kaizen Team Rules
• Kaizen Week Schedule

Module 5: Types of Waste

• Overproduction
• Overprocessing
• Waiting
• Motion
• Transportation
• Inventory
• Rework

Module 6: Kaizen Advanced Concepts

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

Module 7: Introduction to Kaizen

• What is Kaizen?
• Toyota’s View of Kaizen
• Kaizen Philosophy
• Implementing Kaizen
• Kaizen as an Improvement Methodology
• How the Process Works?
• Kaizen Bursts/Blitz Vs Formal Kaizen

Module 8: Kaizen Event

• Characteristics of a Good Kaizen Event
• Deploying Kaizen Events in Situations
• Problems Solved Using Kaizen Events
• Employing Kaizen Will Enable You To
• Kaizen Limitations
• Kaizen as an Improvement Methodology
• Formal Kaizen Event Execution Stages
• Variations on a Theme

Module 9: DMAIC

• Kaizen Working with DMAIC
• Kaizen Events and Tradition Methodologies
• Kaizen Vs Waterfall Approach
• Kaizen ISFs
• Kaizen Lean Toolkit

Module 10: Process

• What is a Process?
• Process Concepts
• Types of Process
• Comparing Process Types
• Advantages of Visual Mapping

Module 11: Process Maps

• Introduction to Process Maps
• Swim Lanes and Process Map Levels
• SOPs and OTGIs
• On the Ground Instructions (OTGIs)
• Process Measurement Points
• List of Criteria for a Good Measure
• Brief Description of Data Collection Planning
• Steps of Data Collection Process
• Identify SPC Charts and Metrics
• Data Collection Sheet
• Frequency and Sample Size
• Evolving Data Collection Plan

Module 12: Introduction to VSM

• Value Stream Maps
• Where are VSM’s Used?
• What is a Value Stream?
• Mapping the Process Types
• Manufacturing VSM
• Creating the “As Is” VSM
• Investigating and Understanding the Process
• Headache Tablets: Value Stream Mapping
• Value Stream Symbols
• Using Swim Lanes to Identify Logical Process Blocks
• Process Boxes

Module 13: VSM Metrics

• Useful VSM Metrics
• Rolled Throughput Yield (RTY)
• Square Wave and Kaizen Burst
• Alternative VSM
• Creating an Improved Process
• Identify Areas of Improvement
• Layout Diagrams and Headache Tablets
• VSM “To Be”
• Steps for Building a Value Stream Map
• Building Your Paper to the Required Standard
• Points for Facilitators and Process Mapping Closedown
• Transactional VSM and How the New Process Works?
• Layout Diagrams

Module 14: Interactive VSMs

• Interactive VSMs Overview
• Interactive Process Concepts
• Format of the Interactive VSM
• Common Rows on the Interactive VSM
• How to Create an Interactive Map?
• Interactive Map
• Interactive VSM
• Interactive VSM Symbols and Measures
• Service Transaction Box

Module 15: Preparation in a Nutshell

• Kaizen Preparation in a Nutshell
• Selecting Suitable Areas for Kaizen
• Office/Transactional/Retail Based Kaizen Opportunities
• Not Everything Can Be Solved by a Kaizen Event
• Formal Kaizen Roles
• Headline on Formal Kaizen Roles
• How the Roles Work Together?
• Sensei/Facilitator/Coordinator
• Kaizen Sponsor and Champion

Module 16: Team

• Team Leader
• Variations on a Theme
• What to Look for in a Good Team Leader?
• Solution Team Member
• Ad Hoc Subject Matter Practitioners (SMEs)
• Recorder
• Getting the Correct Team Mixture
• What to Look for in a Good Team Member?
• Kaizen Approach to Understanding the Process
• Process Borders Definition
• CS&F Web Fulfilment SIPOC

Module 17: Meeting, Charter, and Training

• Pre-Kaizen
• Aim and Agenda of the Kick-Off Meeting
• Kaizen Charter
• Typical Charter Contents
• Purpose of Training
• Suggested Training Agenda
• Mandate: Gateway to Action
• Base Camp
• Event Rules
• Basecamp Checklist

Module 18: Implementation in Nutshell

• Implementation Step in a Nutshell
• Possible Implementation Schedule
• Possible Tools/Techniques and Solutions
• What Makes a Good Solution?
• No Moon Shots
• Seven-Step Problem Solving Methodology

Module 19: Waste and Transaction

• Spotting Waste
• Understanding Transactional Waste
• Ideal Transaction
• Barriers to the Ideal Transaction
• Eliminating Missing Information
• Eliminating Inaccurate Information
• Eliminating Assumptions
• Poor Information Flow
• Facilitator and Team Leader Responsibilities
• Solution Team, Champion, and Sponsor Responsibilities

Module 20: Daily Review

• Daily Review in a Nutshell
• Sponsor Responsibilities in the Daily Review
• Facilitator and Champion Responsibilities in the Daily Review
• Typical Daily Review Agenda
• Short Time-Scales
• Follow-Up in a Nutshell
• How Follow-Up Works?
• Solution Team, Facilitator, Sponsor, and Champion Responsibilities
• Thirty Day Plan
• Checklist