Improving a company's operational efficiency through Lean Production amid crisis expectations

Programme

Goal: To give top managers a new view of production and office processes from the standpoint of Lean production.

Objectives:

1. To consider the possibilities of applying the philosophy and principles of Lean production to increase operational efficiency and involve all company staff in this activity.
2. To explain the Lean methods and tools most effective for use at the enterprise, based on the company's current goals.
3. To gain practice in the applicability of certain Lean production tools for participants' own enterprises through business games and exercises.
4. To become familiar with approaches to forming a long-term corporate programme and with typical problems in applying methods and tools.

Introduction to the concept of Lean production:

1. Measurable goals and expectations of the company for increasing efficiency.

Practical session. Business game, round I. Modelling the organisation of production according to traditional principles.

1. Introduction to Lean production. Basic concepts. 
2. Fundamentals of the business: what is it and why?

Practical session. Assessing the existing fundamentals of the business and the goals of the current period.

1. The concept of «value» for the customer/consumer of a service or product. The concept of the external and internal customer.

Practical session. How to define value and identify the actions that create it. 

1. Understanding waste. Rules for counting and assessing waste.

Practical session. Identifying and assessing waste (efficiency reserves) in a practical exercise or at an operating production site (depending on the enterprise's capabilities). Examining the impact on cost, quality and productivity.

1. Principles and approaches to carrying out change in the company. Causes of resistance. The «human factor» - what to do about it? How to create a basis for improvements.

Practical session. Causes of resistance to change, paradigms that hinder the company's development. Developing alternatives.

1. Basic Lean tools: value stream mapping – a tool for the manager. 

      Methodology and practice of application.

Practical session. Practical work on value stream mapping.

1. Overview of Lean tools, including for office work.

Practical sessions and exercises on applying the tools (problem solving, 5S, standardisation, quick changeover, etc.) 

1. Examples of the results of applying Lean production methods and tools.
2. Lean management.
3. Principles of successful implementation of Kaizen programmes. Developing the programme and its infrastructure. Conditions for successful change.
4. Examples and practice of developing production systems. The role of managers in carrying out change.

Expected result:

1)   Top managers' understanding of the philosophy, principles and tools of Lean production.

2)   Gaining skills in applying basic Lean tools.

3)   Understanding the essence and possibilities of Lean tools for the enterprise.

Note:

A more detailed study of individual Lean tools requires separate courses under separate programmes lasting from 4 to 5 days.