Lean Training Courses

Kaizen Institute USA has developed many practical training courses to help you gain a deeper understanding of lean manufacturing, lean healthcare and lean office covering principles and tools. For most of our lean training courses we offer a 1-day introductory course option as an overview.

We also offer customized, higher level 2, 3, 4 or 5-day workshops to immediately apply what was learned in the workplace. The duration depends on the subject matter of the training and the target area for implementation.

Tell us about your specific Lean training needs, we can design the right course for you.

Lean Enterprise Overview and Simulation

Do you struggle with...?

  • Staying ahead of the competition on quality, cost or delivery?
  • Long lead-times through your manufacturing process?
  • Poor quality?
  • Low productivity?
  • Limited awareness of the need for Lean in your organization?
  • No clear blueprint for operational excellence?

If you answered “yes” to any of these questions, Lean Enterprise Overview + Simulation is the course for you.

Does your organization have a culture of continuous improvement?  Would you like to know the impact the Toyota Production System (TPS) can have on your organization? 

A Lean Enterprise is one that produces defect-free products or services, on time, customized to the needs of the customer, safely and profitably.  Learn the initial steps that need to be taken and how to lay the groundwork to begin your lean transformation.  This course includes an interactive factory simulation (The Pipe Simulation) to drive home the key points of TPS.    

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Value Stream Mapping

Do you struggle with...?

• A commitment to Lean, but no clear idea of how to get started?
• A sense of where the problems are, but no way to spot them?
• A need for in-depth understanding of Lean tools and how they enable flow in a Value Stream?
• Not being familiar with enough of the Lean tools to see the future state?
• No good method to create an action plan?

If you answered “yes” to any of these questions, Value Stream Mapping is for you.

Once you create a map of the current situation, the steps you take to complete your product or service become clear. As you evaluate each step as to whether its Value Added or Non Value Added, you can begin to see improvement opportunities to create the Future State Value Stream Map

The Current State Value Stream Map tells you where you are.  The Future State Value Stream Map tells you where to go.  This course trains you to create both Current State and Future State Maps, understand the tools used to create them and develop the implementation plan to move towards Future State.

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Visual Management

Do you struggle with...?

  • A disorganized workplace?
  • A lack of visibility of status of projects or daily work?
  • Problems that do not become visible until too late?
  • A tendency to manage away from the gemba (actual workplace) through reports and computer dashboards?
  • Lack of understanding of goals by team members?
  • A low awareness of waste and abnormality among people in your organization?

If you answered "yes" to any of the above, Visual Management is the course for you.

One of the fundamental differences between a Lean organization and one that is not continually improving by eliminating waste is that a Lean workplace is a visual workplace.  Various tools known as visual controls are used to clearly identify, label, and mark the workplace.  Once these basics are in place, visual management becomes a system of communication and routine checks that make abnormalities immediately visible.  By making daily, weekly and monthly meetings around these visual management boards a part of the management system, problems are surfaced earlier and resolved quicker.

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5S & Lean Office

"Sure it's a mess, but I know exactly where everything is!"

In your office, can you find whatever you need in less than 30 seconds?

Can anyone else walk in and find what they need in less than 30 seconds? 

The aim of 5S Lean Office is to remove what is not needed, place the necessary items at the point of use and make a clean, visual and high performance workplace.

5S as a foundation for operational excellence

One of the most fundamental activities of any Lean implementation is 5S.  This is no different for Office Kaizen (also known as 'Lean office').  Changing the information transaction process to a Lean Office can begin only after first implementing 5S Lean Office.

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Business Process Mapping

Do you struggle with...?

  • A lack of an overall picture of your information flow?
  • The time it takes to process customer requests?
  • Redundancy and errors in Business Process transactions?
  • Poor communication and teamwork between Business Processes?
  • No clear method to create an improvement plan?

If you answered “yes” to any of these questions, Business Process Mapping is the course for you.

Business Process Mapping is the process of observing and understanding the current condition and drawing a map that becomes your blueprint for a Lean office implementation.  This course gives you the knowledge, the tools and the practice you need to begin using a variety of mapping techniques for the purpose of improving administrative, transactional, engineering or service operations.

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Practical Problem Solving

Do you struggle with...?

  • A lot of planning but very little action?
  • Action but no follow up?
  • Fixing a problem only to have it appear again?
  • A lack of a standard approach to problem solving?
  • Not enough people capable of problem solving?
  • Too much focus on Lean tools and not on actual problem solving?

If you answered “yes” to any of these questions, Practical Problem Solving is the course for you.

Practical problem solving by everyone in the organization is at the heart of the Toyota Production System and a Lean Enterprise culture.  Kaizen is nothing more than the ability to observe the current state, identify the problem and apply practical problem solving skills repeatedly and without end.  These skills are based on the PDCA (Plan-Do-Check-Act) cycle and reinforced by a variety of one-page templates to visualize the problem solving thought process.

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Kaizen Event Team Leader Training

Do you struggle with...?

  • Training people to run a good kaizen event?
  • How to run a successful week-long kaizen event?
  • Having only a couple of leaders capable of leading a kaizen event?
  • Achieving breakthrough results from your kaizen activities?
  • Lack of sustained results from kaizen activities?

If you answered “yes” to any of these questions, Kaizen Event Team Leader Training is the course for you.

There are many way to practice kaizen (continuous improvement) and the five day "kaizen event" is one of the most common.  A good, well-led kaizen event will energize your team, produce amazing results and develop your people.

This class will review the details of running a kaizen event, how to do them well, and what is required from the organization for them to be successful. This class will take the participant through the planning, facilitation and follow up phases of a kaizen event.

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Value Stream Mapping for Lean Healthcare

Do you struggle with...?

  • A commitment to Lean, but no clear idea of how to get started?
  • Long patient wait times and poor patient flow?
  • Not sure what to improve to get the greatest impact?
  • A need for in-depth understanding of Lean tools and how they enable flow in a Value Stream?
  • Not being familiar with enough of the Lean tools to see the future state?
  • Growing demand for services but limited capacity?
  • Isolated improvements that don't seem to result in better patient care or lower costs?

If you answered “yes” to any of these questions, Value Stream Mapping for Lean Healthcare is the course for you.

Value Stream Mapping is the process of observing and understanding the current condition and drawing a map that becomes your blue print for Lean healthcare implementation.  This course will teach you the difference between value and the 7 types of waste and how to identify them through Value Stream Mapping. This course gives you the knowledge, the tools and the practice you need to begin drawing Value Stream Maps for the purpose of improving patient flow or ancillary services productivity and throughput time

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Lean Healthcare Overview

Do you struggle with...?

Continuing to improve safety, quality, cost or delivery?

  • Long patient wait times and poor patient flow?
  • Medical Errors?
  • Need to improve productivity?
  • Limited awareness of the need for Lean in your organization?
  • No clear blueprint for operational excellence?

If you answered “yes” to any of these questions, Lean Healthcare Overview is the course for you.

Do you have a culture of continuous improvement?  Would you like to know the impact that the Toyota Production System (TPS) and Lean Thinking can have on your Healthcare organization? 

A Lean Enterprise is one that produces defect-free services, on time, customized to the needs of the patient, safely and profitably.  Learn the initial steps that need to be taken and how to lay the groundwork to begin your lean healthcare transformation.  This course includes an interactive simulation to drive home some of the key points of TPS and Lean Thinking. 

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Production Preparation Process (3P) for Lean Healthcare

Do you struggle with...?

  • The long time it takes to launch new facility designs?
  • A facility layout created without continuous improvement in mind?
  • Hitting quality and safety levels from opening day?
  • Inflexible equipment and layouts?
  • Finding room within your facility to expand?
  • Waste in your process flow due to existing layout issues?
  • A new facility design that is the same as your existing design, only bigger?
  • A new facility design that looks good but does not improve any of the 7 flows?
  • Architects and contractors making layout decisions instead of your own cross-functional team?

If you answered “yes” to any of these questions, Production Preparation Process for Lean Healthcare is the workshop for you.

Using a variation from the Lean manufacturing world, the Production Preparation Process (3P) is one part of an overall Lean design approach that includes the rapid testing of ideas and the embedding of Lean principles into process and workspace design in the shortest time possible.  With primary focus on patients, the 3P approach challenges us to reinvent the healthcare experience from the ground up –for patients, physicians and staff – to achieve breakthrough results in satisfaction, patient safety, clinical outcomes and operating performance.

Working as a cross-functional team, clinicians, operations staff and lean experts work together in redesigning a healthcare facility and processes to optimizing the 7 flows of healthcare.  The objective is to provide from day one of implementation a process design with100% quality of care, flowing with no waste, in a safe and effective manner.

Be expected to “Get your hands dirty!” as you try out and model your design ideas and demonstrate what it will take to make a concept actually work.

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5S & Workplace Organization

Do you struggle with...?

  • What is 5S?
  • How can I apply 5S in an workplace environment?
  • What techniques can be used to get rid of unnecessary items?
  • How to use a 5S Red Tag?
  • How difficult is 5S to understand and implement?
  • How long should I keep unnecessary items?
  • What are the prerequisites to implement 5S?
  • What are the phases or steps to implement 5S?
  • How can I sustain the 5S results?

If you answered “yes” to any of these questions, 5S & Workplace Organization is for you!

5S is the basic foundation for continuous improvement for any company which aims to enhance safety, quality, delivery and cost. This training will allow the participant to learn in depth what 5S is and how to apply it immediately to quickly improve the workplace. 

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SMED and Quick Changeover

Do you struggle with...?

  • Long changeover times on your equipment or production lines?
  • High inventories driven by large lot sizes due to set up and changeover time?
  • A lack of capacity due to long equipment changeover time?
  • Lack of a repeatable changeover process?

If you answered “yes” to any of these questions, SMED and Quick Changeover is the course for you.

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Kanban

You already know that Lean is the way to go, you might even be aware that the Pull system is the better way of production without excessive WIP inventory, but …

  • How can the kanban system be implemented in my company?
  • What if kanban causes or may cause material shortages and production stoppages?
  • What are the prerequisite before the implementation of kanban?

Or, simply you struggle with...?

  • Your customer’s demand that you respond more effectively to their kanban system?
  • Inventory building up due to push production?
  • Production lot sizes not synchronized with actual demand?
  • Shortages of parts or materials from suppliers (internal or external)?

If you answered "yes" to any of the above, Kanban might be the course you need, in order to explore the possibility for your organization to be Lean.

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TPM (Total Productive Maintenance)

Do you struggle with...?

  • Lost capacity due to unplanned equipment breakdowns?
  • Lack of machine operator ownership of equipment upkeep?
  • Overloaded maintenance workloads?
  • Lack of good metrics to track lost time?

If you answered “yes” to any of these questions, TPM is the course for you.

TPM (Total Productive Maintenance) is comprehensive approach to improving equipment uptime and capability through a program of total involvement by workers, engineers, maintenance personnel and management.  Lean manufacturing requires stable and reliable processes to maintain smooth flow, and TPM is a way for your organization to build this stability.

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Standard Work

Do you struggle with...?

  • The time required training new workers?
  • Inconsistent results from training?
  • Variable cycle times between workers?
  • Inability to meet takt time?
  • Inability to sustain kaizen event results?

If you answered “yes” to any of these questions, Standard Work is the course for you.

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Production Preparation Process (3P)

Do you struggle with...?

  • The long time it takes to launch new designs into production?
  • Designing products with continuous improvement in mind?
  • Hitting quality, volume or cost targets at production startup?
  • Inflexible equipment?
  • Finding room within your facility to expand?
  • Designing a new production line or entire facility with lean principles in mind?
  • Batch equipment that does not support continuous flow?
  • High equipment investment cost?

If you answered “yes” to any of these questions, Production Preparation Process is the workshop for you.

The Production Preparation Process (3P) can be defined as the process of designing products and their associated production process methods in the shortest time possible that support Lean principles such as one-piece flow, building quality into the process, quick changeover, and flexibility.  Production Preparation Process involves consideration and testing of various process alternatives, the cross-functional team approach, and providing feedback to product design in order to improve the production process.

Be expected to “Get your hands dirty!” as you try out and model your design ideas and demonstrate what it will take to make a concept actually work.

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Thank you for choosing Kaizen!

Consulting, training and tour inquiries:

Kaizen Institute USA

13000 Beverly Park Rd
Ste. B
Mukilteo, WA 98275 USA

Toll Free: +1 888-464-3622 
Fax: +1 425 368 5240
Email: us@spam.kaizen.com

For global partnership opportunities:

Americas Regional Operations- HQ
KICG-USA, Inc.
7137 E Rancho Vista Dr., Ste. B11
Scottsdale, AZ  85251 USA


Toll Free: +1 888-464-3622 
Fax: +1 480 320 3479
Email: kicg@spam.kaizen.com