Process Optimization Level I (Introduction)

Transcription

1 Process Optimization Level I (Introduction) 8 Hours A hands-on, interactive introduction to Business Process Optimization Focused on the most effective tools & concepts from the many process improvement methodologies, including Lean, Six Sigma, PDCA, Just-In-Time, TQM and 4DX. 1. Identify the Opportunity 8 Wastes SWOT Project Selection 2. Analyze the Process Customer Value Voice of the Customer Critical to Quality Process Measurement Measure, Metrics, KPI Performance Dependence Diagram Affinity Diagram Fishbone Diagram Pareto Principle Process Mapping 8 Wastes Value Added & Non-Value Added Activities FMEA 3. Optimize the Process Theory of Constraints Flow Push vs Pull Mistake Proofing Visual Controls Standard Work Line Balancing 4. Sustain the Improvement Monetizing Process Improvements Control Plan

2 Process Optimization Level II (Intermediate) 8 Hours A hands-on, interactive, intermediate-level Business Process Optimization course. Focused on the most effective tools & concepts from the many process improvement methodologies, including Lean, Six Sigma, PDCA, Just-In-Time, TQM and 4DX. 1. Identify the Opportunity o Customer Interview o Problem Statement o Goal Statements o A3 Approach 2. Analyze the Process o RACI Chart o Discrete vs Continuous Data o Data Sampling o Describing Data Numerically o Mean, Mode, Variance, Std Dev o Basic Statistics o Parameters o Confidence Intervals o Sample Size o Distributions o Hidden Factory o Common Cause vs Special Cause Variation o 8 Wastes o Value Added & Non-Value Added Activities o Intro to Value Stream Mapping o Impact vs Effort Chart 3. Optimize the Process o 5S o Theory of Constraints o Work Cells o Takt Time o Quick Changeover o Implementing Change 4. Sustain the Improvement o Change Management o Kaizen o Control Plans o Behavioral Leadership

3 Project Management Level I (Introduction) 8 Hours An overview of the fundamental tools and concepts of Project Management & Administration. Follows the Project Management Body of Knowledge (PMBOK) Five Phases of Project Management

4 INTRO & IDENTIFY Definitions PMBOK Project Structure o Project Life Cycles o Project Management Phases o Phase Key Actions & Documents 1. INITIATE Feasibility Study Project Charter o Business Case o Problem Statement o Goal Statement o Objectives Statement o Performance Dependence Diagram o Deliverables & Acceptance Criteria o Boundaries (Scope) o Estimated Project Costs o Project Benefits o Return on Investment (ROI) o Initial Risk assessment o Initial Issue assessment o Assumptions o Constraints o Roles & Responsibilities 2. PLAN Project Management Plan o Scope Work Breakdown Structure o Schedule Define Activities Sequence Activities Activity Resources Activity Duration Develop Schedule o Management Plans Risk Management Change Management 3. EXECUTE Team Development Establish Measurement 4. MONITOR & CONTROL Monitor o Issue Log Control o Change Requests o Change Request Log 5. CLOSE Reasons for Project Failure Lessons Learned Team Recognition Project Management & Process Optimization Level I 16 Hours A powerful, easy-to-understand overview of the fundamental tools and concepts of both Project Management and Business Process Optimization (Lean Six Sigma). Follows the Project Management Body of Knowledge (PMBOK) Five Phases of Project Management

5 INTRO & IDENTIFY Definitions PMBOK Project Structure o Project Life Cycles o Project Management Phases o Phase Key Actions & Documents Identification o SWOT Analysis o Feasibility Study 1. INITIATE Customers o Customer Value o Voice of the Customer o Critical to Quality Project Charter o Business Case o Problem Statement o Goal Statement o Objectives Statement o Performance Dependence Diagram o Deliverables & Acceptance Criteria o Boundaries (Scope) o Estimated Project Costs o Project Benefits o Return on Investment (ROI) o Initial Risk assessment o Initial Issue assessment o Assumptions o Constraints o Roles & Responsibilities 2. PLAN Project Management Plan o Scope Work Breakdown Structure o Schedule Define Activities Sequence Activities Activity Resources Activity Duration Develop Schedule o Management Plans Risk Management Change Management Process Review & Planning o The 8 Wastes o Process Mapping o Value & Non-Value Added o Theory of Constraints o Balanced Work o Flow, Push, Pull 3. EXECUTE Team Development Establish Measurement 4. MONITOR & CONTROL Monitor o Issue Log o Root Cause Analysis o Cause Elimination vs Problem Solving o Performance Dependence Diagram o Affinity Diagram o Fishbone Diagram o Pareto Principle o FMEA Control o Change Requests o Change Request Log o Mistake Proofing o Visual Controls o Standard Work 5. CLOSE Reasons for Project Failure Lessons Learned Team Recognition Rapid Root Cause Analysis & Elimination 4 Hours Pre-requisite: None

6 A proven, easy-to-learn 5-step methodology to rapidly analyze & eliminate the Root Cause of any problem or issue through assignable, measureable action items. Useful for ANY employee, in ANY position, in ANY industry. Introduction o Cause Elimination vs Problem Solving o 5-Why & Why Tree Step 1: Determine the Metric o Process Measurement, Metrics & KPIs o Acceptable Limits o Voice of the Customer & Critical to Quality Step 2: Establish the Dependencies o Performance Dependence Diagrams o Affinity Diagram o Process Stability & Variation Step 3: Breakdown the Cause Categories o Fishbone Diagram o Pareto Principle Step 4: Determine the Risk o Create FMEA Step 5: Assign Actions o Create action items from FMEA Kaizen Event Leader

7 4 Hours Pre-requisite: Process Optimization Level I (Introduction) Provides in-depth training to lead a Kaizen Event, which focuses on making radical, quick changes to streamline, optimize or enhance a process or service. Reinforces the use of Process Optimization tools throughout the event to identify and resolve the current constraints/issues and design an optimized future state. Introduction What is Kaizen? When to utilize a Kaizen Event Pre-Kaizen Event Selecting the team Determine the duration Event Charter Go to the Gemba Process Mapping & Validation Measuring Key Process Variables Common Pitfalls Event Sign-Off Kaizen Event Team Building Team Facilitation Event Introduction o Charter Review o Process Optimization Overview Review the Current State o Process Maps o Baseline Metrics o Collecting Data Analyze the Current State o Performance Dependence Diagram o Value Added & Non-Value added steps o 8 Wastes o Cause & Effect Diagram o Theory of Constraints o Brainstorming Improve the Current State o FMEA o Pull, Flow, Error-Proofing, Standardization o Piloting a Solution o To-Be Process Map o Establish Goals & Metrics o Roles & Responsibilities o Change Management o Control Plan Event Review & Feedback Post-Kaizen Event Tracking the changes Ensure accountability Project Close-Out

8 Advanced Process Mapping 4 Hours Pre-requisite: Process Optimization Level I (Introduction) Provides in-depth training of a structured approach to modeling, analyzing and improving business processes through Process Maps and Flowcharts. Reinforces the use of Process Optimization (LEAN) tools to help identify and remove waste within the process for increased efficiency and optimize future state processes.

9 Introduction o Why Map a Process? o Flowchart Standards for Symbols, Content & Structure o Process Mapping Techniques & Levels o Flowchart (Swimlane) Diagrams Map the Current State o Gathering the information o Scoping the Process o Go to the Gemba o Rework Loops o Measuring Key Process Variables Cycle Time Takt Time First Pass Yield o Common Pitfalls o Process Map Validation Analyze the Current State o The Hidden Factory o The 8 Wastes o Value Added & Non-Value added steps o Improving the Value Added Steps o Cause-and-Effect relationships of Process Variables o Handoffs & Joint Responsibilities Map the Future State o Process Redesign Principles o Common Pitfalls o Future State Metrics o Implementing the Change