Process Excellence - Implementation of Lean Management and Six Sigma
Program Duration ( 9 - 12 months)
Process Excellence is about making our processes efficient and effective through elimination of waste and reducing variation and bringing about organisational transformation over 9 - 12 months. It is a systematic hands-on approach through training, coaching, implementing live projects, hand-holding the client during the entire improvement cycle and demonstrating results across the value chain - be it productivity, lead time reduction, OTD improvement or inventory reduction through the period of transformation. From initial assessment of the Operations to design and implementation of Lean architecture - through Hoshin Kanri (policy deployment), capability building, motivating workforce to passionately imbibe Toyota principles of Genchi Gembutsu (get out and see), Kaizen, Challenge, Respect and Teamwork through team based problem solving and continual improvement initiatives across the organisation.
Process Excellence - Module 1
Duration : 12 days
360 degree Lean Assessment
Duration 1 -2 days
In this module a 360 degrees Lean Competency Assessment (LCA) is carried out to assess the areas of strength and improvement of the existing operations with regards to Lean Implementation. A lean score across 14 categories are assessed and competency score for each area and cumulative lean competency are evaluated. Based on the score the Organisational Excellence Module is worked on.
Training on Lean Managent
Duration 5 days
A comprehensive lean training over 5 days covering fundamental aspects over 8 modules of lean Strategic Planning ( Hoshin), 5S & Visual Management, Value Stream Mapping, Standard work, Zone Control, Flow, A3 - Problem Solving, TPM, Set-up Reduction, Gemba & Lean Training.Lean Operating Model. Connectivity, Kanban, Raw Material Strategy, Leadership Training & Standard Works.
Black Belt Training on Six Sigma
Duration 6 days
6 days coaching on yellow belt module which would cover extensively various aspects of six sigma - Six sigma philosophy, project selection, roles and responsibility of project sponsor, champion, project leader and team members, DMAIC process, funneling methodology - problem definition, tools and techniques for analysis and improvements like DOE, ANOVA, Multivari Analysis, Controls Charts.
Process Excellence - Module 2
Duration :10 days
Lean Six Sigma Implementation - Hoshin Planning, Mapping Value Stream and Standard Work Preparation
Process Excellence - Module 3
Duration:10 days
Lean Six Sigma Implementation : Waste Elimination through Jidoka, Problem Solving and TPM.
Process Excellence - Module 4
Duration :12 days
Lean Six Sigma Implementation : Process Change Implementation, Kanban and Continuous Improvement
Process Excellence - Module 2
Duration :10 days
Lean Six Sigma Implementation - Hoshin Planning, Mapping Value Stream and Standard Work Preparation
- Hoshin Planning ( 3 - 5 years Operational KPI & targets )
- 5 S Activity - Live Group
- Waste Walk (Gemba) - Identification of 8 wastes and 3 Ms
- Value Stream Mapping (VSM ) ( 3 product lines) - Live Group Activity
- Genchi Gembutsu - Zone Control Activity ( Production Function ) - Live Group Activity
- Preparation of Standard work ( Production Function )
- Flow Production
- Problem Solving ( A 3 ) - 4 projects
- Six Sigma Tools ( Part 1 ) - 4 projects
- Define Phase
- Measure Phase
Process Excellence - Module 3
Duration:10 days
Lean Six Sigma Implementation : Waste Elimination through Jidoka, Problem Solving and TPM.
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- Zone Control Activity - Live Group Activity ( 2 Support Functions ) - Live Group Activity
- Preparation of Standard work ( for 2 Support Function )
- Jidoka & Failsafing
- 8 Step Problem Solving with A3 - 4 Projects ( contd.)
- Six Sigma Tools ( Part 2) - 4 Projects ( contd.)
- Measure Phase ( contd.)
- Analyse Phase
- TPM & OEE ( 4 lines )
- Set -up Reduction
- SMED
- Lean Operating Model
Process Excellence - Module 4
Duration :12 days
Lean Six Sigma Implementation : Process Change Implementation, Kanban and Continuous Improvement
- Leadership Training
- Building Team engagement and Culture - Toyota Principles
- Connectivity
- JIT and Pull System
- KANBAN
- Kaizen Events
- Raw Material Strategy
- Problem Solving with ( A3)
- Six Sigma Tools ( Part 3)
- Improve
- Control
- 360 degree lean Re-assessment and Awards nomination ( Lean Award - Bronze, Silver , Gold , Platinum)
- Review KPI and targets ( fix targets for True North)