Lean A3 Problem Solving - Course Description

 

This course is especially designed to develop skills and knowledge on how to solve problems and provide an opportunity to ‘learn by doing’ by working on actual problems found at the participants work-place:

 

1)    This activity-based training takes participants in a step by step method through the A3 thinking process (a series of divergent-convergent steps to solve problems). It makes use of numerous activities and 3 simulation runs to tightly couple and integrate the knowledge and learning of key lean tools with the A3 problem solving process. Learn by doing is a key feature of this training where participants will learn the A3 problem solving process and several key lean tools and techniques through the practical exercises, simulation runs and working on actual problems from the participants work-place.

 

2)    To make best use of time the problems each team will work on will need to be pre-identified before the class. A project charter is prepared by each team and submitted before the class (optional).

 

The course objectives are as follows:

 

·         Learn the concepts, principles and benefits of Lean Management

·         Acquire skills on key Lean tools and techniques

·         Learn the Lean A3 problem-solving approach to solve problems at your work-place

·         Hands-on application of these skills to resolve actual problems at your work-place

·         Learn through hands-on practice, activities, demos and simulations

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Course Content:

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Module 1 – Setting the Stage

·       Leadership Case for Change

·       Where did Lean come from?

·       TIMWOOD-I Wastes

·       Post Course Expectations

 

Module 2 – Specifying Value

·       Principles of Lean

·       What is A3 Thinking?

·       SMART Goals

·       SIPOC Diagram

·       Stakeholder Management

 

Module 3 – Identifying the Value Stream

·       Value Streams

·       Gemba Walk

·       Gemba Walk Table

·       Simulation Round 1 + De-brief

·       Developing Value Stream Maps

 

Module 4 – Improve the Flow & Introduce Pull (Part 1)

·       Root-Cause Analysis

o    Fishbone Analysis

o    The 5 WHYS

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Module 5 – Improve the Flow & Introduce Pull (Part 2)

·       Eliminate Obvious Waste

·       Impact of Batch Size

·       Workload Balancing

·       Applying 5S

·       Potential Counter-Measures

·       PDCA

·       Simulation Round 2 + De-brief

 

Module 6 – Improve the Flow and Introduce Pull (Part 3)

·       Spaghetti Diagram

·       Load Levelling

·       Mistake Proofing

·       Sustaining the Gains (Lean SOP & VM)

 

Module 7 – Pursuing Perfection

·       Manage & Communicate visually

·       Visual Management and Huddles

·       See, Know, Act & Learn Together

·       Simulation Round 3 + De-brief

·       Elements of Standard Work

·       Where to begin building Standard Work?

 

Module 8 – What are the Next Steps

·       Post Course Expectations

·       Roles & Responsibilities

·       Next Steps

·       Closing