Operational excellence requires a disciplined approach to eliminating waste, standardizing work, and engaging teams in continuous improvement. This course covers Lean Six Sigma, 5S, Kaizen, and Root Cause Analysis as integrated tools. Participants will lead improvement events and apply structured problem-solving.
- Apply Lean Six Sigma principles to reduce variation
- Implement 5S for workplace organization
- Facilitate Kaizen events for rapid improvement
- Conduct root cause analysis on operational failures
Day 1: Lean Six Sigma Fundamentals
- DMAIC methodology overview
- Identifying waste (TIMWOODS)
- Process sigma calculation basics
Day 2: 5S Workplace Organization
- Sort, Set in order, Shine, Standardize, Sustain
- Visual management techniques
- Conducting a 5S audit and scoring
Day 3: Kaizen for Rapid Improvement
- Kaizen event planning and team selection
- PDCA cycles in Kaizen
- Real-life Kaizen simulation
Day 4: Root Cause Analysis (RCA)
- 5 Whys, Fishbone diagram, FMEA
- Data gathering for RCA
- Differentiating root cause from symptoms
Day 5: Integration & Improvement Culture
- Combining Lean, 5S, Kaizen, and RCA
- Sustaining gains through standard work
- Building a continuous improvement culture
Operations managers, continuous improvement leads, process owners, team leaders.
Learning Outcomes:
- Define DMAIC projects for operational issues
- Conduct a 5S audit and corrective plan
- Lead a Kaizen blitz event
- Use 5 Whys and fishbone diagrams effectively
Target Competencies:
- Behavioral: Process discipline, collaboration, change readiness
- Technical: Lean tools, Six Sigma statistical thinking, Kaizen facilitation