Course Description

This course is designed to equip students with the foundational knowledge of Lean and A3 Problem-Solving, and will cover the following topics: 

• Intro to Lean 
• A3 Problem-Solving 
• Process Maps 
• The 8 Wastes 
• Cause Analysis – 5 Why, Fishbone, Cause & Effect Diagrams 
• PDCA (Plan, Do, Check, Act) 
• Standard Work 
• Error Proofing 
• Visual Management 
• 5S 
• Going to Gemba (Process Confirmation) 
• Current State Value Stream Mapping 
• Lean Metrics 
• Future State Value Stream Mapping 
• Flow & Pull Systems 
• Workplace Design and Layout 

The focus of this course is on applying the concepts as students learn. Learning materials will be a blend of case studies, self-paced e-learning through modules and videos, and practical application. Students will have the opportunity to apply the learning through an in-class simulation and outside of class with a small improvement project. By the end of this course, students will be able to effectively apply A3 problem-solving using lean concepts and tools. 

Course Outline

1. Overview
2. A3 Problem Solving & Problem Statements
3. Current State Analysis
4. Current State & Root Cause Analysis
5. Root cause Analysis & Countermeasures
6. PDCA & Experiment Design
7. Standard Work
8. 5S
9. Error Proofing & Visual Management
10. Sustaining Improvement
11. The Value Stream
12. Designing Flow
13. The Lean Leader & Lean Management Systems
14. Final Presentations

Learner Outcomes

At the end of this course, the learner will:

• Be able to identify the 8 wastes in a process (DOWNTIME) 
• Be able to capture current state, utilizing tools such as a Waste Walk, Process Map, and Occurrence Tracker 
• Be able to set a SMART goal (Specific, Measurable, Attainable, Relevant, Time-Bound) 
• Be able to analyze causes of a problem using the 5 Why technique, fishbone brainstorming, and cause & effect diagrams 
• Be able to follow a structured Plan, Do, Check, Act cycle to implement and test countermeasures 
• Describe how to create & maintain standard work 
• Describe how error proofing, visual management, and 5S can be used to support process improvement efforts 
• Explain the basic tenants of a process value stream