Draw the process step by step to understand how the company is currently functioning.
Identify unnecessary actions and delays that lead to wasted time and money.
Set up operations without downtime to ensure tasks are completed on time.
Day 1: Mapping (Current State Analysis)
Focus of the day: Basic concepts, process visualization, and identification of hidden losses. * Introductory block * Introduction to training: goals, objectives. * Kaizen tool house. * Process visualization. * DMAIC algorithm. * Practice: Immersion * Business game “Production” (round 1). * Module 1: Macroanalysis (“Eagle's view”) * Mini-lecture: CPSSC. Stages of construction. * Exercise: Building the current state CPSSC according to the game. * Module 2: Microanalysis (“Ant’s view”) * Mini-lecture: Measurement and analysis tools. * Practical exercises block according to the game: * Conducting a stopwatch study. * Completing the operation diagram. * Completing the operator loading diagram. * Building a spaghetti diagram. * Day’s conclusion * Exercise: Calculating the stream efficiency.
Day 2: Flow. “Just-in-Time” Method
Focus of the day: Applying lean production principles and designing the target state. * Introductory block * Reflection on the first day. * Module 3: Flow optimization * Mini-lecture: “8 principles of flow”. * Exercise: Practicing 8 principles. * Practice: Transformation * Business game “Production” using 8 principles of flow. * Module 4: Target state * Mini-lecture: CPSSC of the future state.
Day 3: Gemba and attestation
Focus of the day: Working in real conditions and knowledge testing. * Walkout to production * Visit to Gemba. * Module 5: On-site practice * Exercise: Practicing mapping skills on the existing process at Gemba. * Course completion * Testing: Checking knowledge on course materials. * Summarizing, collecting feedback.