Course Outline

Module 1: Kaizen Overview

• Concepts and Principles of Kaizen
• Kaizen Application Insight
• Crucial Implementation Issues and Strategies
• Maintaining Kaizen Implementation

Module 2: Kaizen Strategy

• Role of Management
• Planning a Kaizen Continuous Improvement Programme
• Change Management
• Tailoring the Culture to Kaizen
• Kaizen Tools
• Selecting and Handling Projects
• Identifying Teams to Implement Kaizen
• The Roles of Team Members
• Performance Metrics
• Successful Kaizen Implementation

Module 3: Kaizen Tools

• Kaizen Quality Improvement Tools
• 7QC Tools and their Application
• Check Sheet
• Pareto Chart
• Histogram
• Scatter Diagram
• Process Map
• Cause and Effect Diagram
• Process Map
• Control Chart

Module 4: The Kaizen Week Approach

• Kaizen Week Preparation
• General Kaizen Week Framework
• Facilitation Keys
• Kaizen Team Rules
• Kaizen Week Schedule
• Overproduction
• Over processing
• Waiting
• Motion
• Transportation
• Inventory
• Rework

Module 6: Kaizen Advanced Concepts

• Kaizen Tools and Techniques
• Change Management
• Leadership
• Tailoring Culture
• Aligning Improvement Programs to Business Objectives
• Introduction to Value Street Mapping
• Selecting and Managing Projects
• Developing a Kaizen Roadmap
• Role of the Kaizen Leader
• Planning and Organizing Effective Kaizen Events

Module 7: Kaizen Leader Training

• Leadership and Change Management
• The Role of Kaizen Leaders
• The Relationship between Intensive Kaizen Events and Long-Term Kaizen Projects
• Develop a Kaizen Roadmap
• Effective Kaizen Events/Projects Framework
• Kaizen Tools and Forms

Module 8: Mapping of Process and Value Stream

• Process Mapping Overview
• Value Stream Mapping Principles and Methodology
• Mapping Tools and Symbols
• Process Mapping and Value Stream Mapping of the Current State
• Process Mapping and Value Stream Mapping of the Future State
• Using Process Maps
• Value Stream Maps
• Prioritizing and Selecting Kaizen Projects
• Identify Project, Champion, Project Owner
• Develop Project Charter and Project Plan

Module 9: Kaizen Project Implementation

• Identify the Kaizen Project
• Establish the Project Structure
• Prepare the Kaizen Event
• Map Current State for the Kaizen Project
• Identify Areas for Improvement
• Map Future State
• Cost and Benefit Analysis of Projects
• Implementing Future State Improvements
• Post-Project Review and Follow-Up
• Identify Further Areas for Improvement/Skills Development
• Project Presentation