Lean Practical Problem Solving

• Agenda • Registration • 

Problem Solving is the foundation of the Toyota Way. The tools of a lean production system are designed to identify problems. Do you have standardization and the expertise at all levels of your organization to solve them? The extent that you train and engage your organization in problem solving will ultimately determine your success in the lean journey. This two day class includes:

• Connecting values of lean to problem solving
• Connecting lean tools to problem solving
• Problem Identification
• Solving Problems in a team – Group Facilitation Tools
• Most used Quality Tools such as Check-sheet, Pareto, Tree Diagram and Affinity
• 8 step method with interactive exercises and demonstration of competency
• Implementation strategies for your organization

Agenda

Day 1
Module I – Values and Culture – (30 min)

• Toyota Overview (2 spheres- 5 values)
• Philosophy and Values of Lean – The Toyota Way
• Hoshin Cascade – Annual Planning-KPI-Visualization-Standardization

Module II – Quality/Problem Solving Tools/Visualization – (90 min)

• Bar/Line (exercise)
• Check sheet (discussion)
• Pareto (exercise)
• Fishbone (discussion- brainstorm vs. cause/effect)
• Tree Diagram(discussion)

Module III – Introduction Land cruiser Simulation and Problem Solving & Step 1 (150 min)

• Land cruiser Round 1 (starting at a Round 2 level)
• Overview of the PDCA process
• Let’s have a kaizen round to practice PDCA- you have 20 min to make improvements – Round 2 *yamazumi creation*
• Definition of a problem (How Toyota views problems- Mr. Ohno reference)

• ID the purpose of your work (my work exercise)
• ID the ideal situation and Ultimate Goal
• ID the current situation
• ID the gap between ideal and current situation
• What is our Current Situation for Round 2 of the Land cruiser? Fill out TBP flowchart

Module IV – Step 2 - Divide and Process & Step 3 - Goal Setting (120 min)

• Divide up the problem
• ID problem prioritized problem
• ID the point of cause by seeing the process
• ID the Problem to Tackle
• Make the commitment
• Set specific, measurable, achievable, realistic and timely goal
• Break up into teams and let’s breakdown each process of the Land cruiser using the TBP flowchart

Day 2
Module V– Step 4 - ID Root Cause & Step 5 - ID Countermeasures (120 min)

• ID potential causes
• Go & See at the source and verify actual causes asking “Why?”
• ID the root cause
• ID potential countermeasures
• Narrow down the countermeasures to the most practical and effective
• Communicate with others (nemawashi)
• Create a detailed action plan (what, who, where, when)
• Fill out your TBP flowcharts for Step 4 and 5
• Run Round 3 of the Land cruiser and document success of countermeasures
• Document and modify if necessary – prepare for Round 4 to check modifications

Module VI– Steps 6, 7 and 8 (30 min)
Step 6 - Implement Countermeasures

• Quickly and as a team, implement countermeasures
• Report, Inform and Consult
• Never give up, and proceed to the next step quickly

Step 7 - Check process & results

• Check process and results and communicate to all stakeholders
• Evaluate from three key viewpoints: Customer’s, Company’s, and Yours
• Understand and learn from failures and success

Step 8 - Standardize and Share Success

• Standardize the effective countermeasure(s) to prevent reoccurrence
• Share your success with other affected areas
• PDCA next improvement opportunity
• Review and Summary
• OJT Application Discussion

Module VII- A3 Writing (180 min)

• A3 purpose – communication tool – nemawashi
• Different types of A3’s
• A3 PPT discussion – A3 formatting
• Each team will break into their Land cruiser teams and write an actual A3 on their process using their TBP flowcharts
• Exchanging of A3’s sharing and feedback
• Wrap up- Evaluation

Registration Fee
$1,995.00

Cancellations - Cancellations are subject to a service charge of $100.00. Confirmed registrants who do not attend, or cancel less than seven days before the course are responsible for the entire fee. You may send a substitute.

to register online

For General Information and
Public Course Registration Contact:
Sandra Dunn
Email:sdunn@engr.uky.edu
Phone: 859-257-6262, ext. 214
Toll Free: 800-227-6268
Cell: 859-338-3742

For Customized Solutions or
Dedicated Training Contact:
HeatherMichele Adkins
Email:hadkins@mfg.uky.edu
Phone: 859-257-6262, ext. 458
Toll Free: 800-227-6268
Cell:859-684-0311