Key Concepts of Lean - Understanding the Toyota Production System (2 Day Class)

Description:
This two-day hands-on workshop is designed for individuals and teams that want to gain a better understanding of the components and underlying philosophy of lean, based on the Toyota Production System (TPS), and how the elements and philosophy work together to create a Lean Enterprise.

The workshop is a mixture of lectures, videos, discussions, and a simulation. The factory simulation will help you understand the concepts of flow, pull, takt time, kaizen, and work cell design in a total business system context.

Short videos from the shop floor will illustrate different aspects of TPS, including how different pull systems operate. You’ll run imaginary companies that are all part of a value stream delivering products to end customers in order to experience first-hand the impact of variability on a value stream and the lean systems used to fight this variability. Small group discussions will give you opportunities to share best practices, reflect on your learning, and develop new solutions to bring back to your organization.

Benefits:
You will learn the key tools and how they fit together under a business system philosophy designed to continuously improve competitiveness by achieving the highest quality, lowest cost, and shortest lead time. You’ll understand why lean is fundamentally different from and superior to business models based on mass production.

This workshop will demonstrate the step-by-step thought process for implementing a lean transformation and how to extend it beyond your organization to improve supplier performance and customer satisfaction. You will discover new insight into lean management philosophy and its methods as well as the organizational structure and change management methods you’ll need for implementing lean in your business.

Course Outline:
Focusing on three key areas – People, Process and Purpose – the program explores the entire Toyota Production System and how it creates a Lean Enterprise.

People
The Toyota Production System is at heart a people-based system and successful lean transformations must be based on a people system. In the course of the workshop, we will discuss selection, training, involvement, and supervisory practices that create the foundation for lean.

Process
In order to get real sustainable results in safety, quality, cost, delivery, and morale, one must bring all the tools of the Toyota Production System to work together as a system. Items covered include:

• Stability, flow, leveling, pull, and kaizen
• The PDCA (plan, do, check, act) discipline that holds the process together and improves it on a continuous basis

Purpose
How all the functions, individuals, and systems work together to deliver true value to customers creating competitive advantage and lasting business results. Items covered include:

• The role of management in creating and supporting a Lean Enterprise
• Hoshin Planning / Policy Deployment and its role as a management system in a Lean Enterprise
• The challenges organizations face in implementing a lean transformation and suggested methods to deal with those challenges

Who Should Attend:
Individuals or teams with little to moderate experience and exposure to lean (TPS) who are looking to increase their understanding; managers who want an understanding of the total scope of implementing lean.

• Lean Solutions
• Lean Thinking, Second Edition

Our educational events are designed to cater to a limited number of participants. If you must cancel a registration, refunds can be issued until the set refund date (20 business days prior to the start of the workshop series). After that date, no refunds will be processed. If you cancel after that date, you will be given a credit for the full amount paid, good for one year (for either yourself or someone else in your organization). You are responsible for contacting LEI to facilitate receiving the credit. To cancel please call LEI at (617) 871-2900.