Basic Structure:
INTRODUCTION
- Origins
- Lean Program benefits
- Lean in the Business Environment
- Cynefin Framework: when Lean is better than the other methodologies
- Lean application in manufacturing processes and administrative processes
- The 5 principles: Value, Value flowchart, continuous flow, pull flow, seeking perfection
- Pull vs Push vs Hybrid Systems: Advantages and Disadvantages
- TPS house – Toyota Production System
- Kaizen
- Concepts of added value to customer (VA), not added value (NVA), and value added only to business (BVA)
- The 8 wastes
HOSHIN KANRI
- Introduction to strategic planning
- BSC x Hoshin Kanri
- Definition of value to customer
- Lean strategy deployment: Roadmap
- Vertical and horizontal alignment
- KPIs
- Definition of goals
- Goals deployment: strategic, tactical, and operating levels
- A3 methodology
- Communication planImplementation of case tools
VALUE FLOWCHART: CURRENT STATUS
- Introduction to value flowchart
- Prioritization: flowchart(s) to be optimized
- Mapping and Symbols
- Current Status Mapping
- Learning to see: Identifying the 8 wastes in the value flowchart
- Takt, Lead, Process e Cycle Times
- Bullwhip, whiplash effect
- Disintegration of the logistic and productive chains
- Particularities on current status mapping in administrative processes
- Implementation of tools in the case
VALUE FLOWCHART: FUTURE STATUS
- Bases for future status: Leveling (Heijunka) and Standardized work
- Implementing 5S: far beyond “housekeeping”
- The pillars of future status: Jidoka concepts and Just in Time
- Jidoka: Making problems visible, Solving workstation problems, Help chain, Andon, Poka-Yoke, Health and Safety in the Work, Eliminating wastes
- Just in time (Doing what is needed, when it is needed, and in the needed amount): pacing the flow (according to Takt time), making the streamline flow, pull systems/ Kanban, SMED/quick setup, Integrated Logistics, Work cells, Lean Layout, Bottleneck resources, and Theory of Restrictions.
SUSTAINABILITY
- Traditional vs Lean Leadership
- Leadership with respect
- Genchi Genbutsu
- Visual Management
- Results Monitoring and maintenance of standards
- Labor flexibility
- Sustaining 5S
- Change Management
- Stakeholders management
- Obeya Room
- Lean Audits
- Implementation in exercises / simulation
- Assessment

Pre-Work: video classes on SETA virtual platform