kaizen college - intrexx xtreme · the kaizen college training program provides practical training...

KAIZENCOLLEGE

Continuous improvement is essential to the strategy of the world’s best companies.

For it to be successful, team members of all levels must have a dedicated involvement. This is what helps boost continuous improvement ideas and implement best work

practices.

The Kaizen College Training Program provides practical training at all hierarchical levels, as well as a space for reflection and exercising methods of improvement. It is about developing continuous improvement skills in all team members to enable improvement of every process.

We hope that Kaizen College’s training offer is recognised for its added value in the development of Kaizen Lean Continuous Improvement skills.

Euclides CoimbraSenior Partner & Managing Director - Kaizen Institute Western Europe

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Both the content and delivery were excellent. The pace of the course and combination of theory and practical exercises were just right. I came away fully informed and aware.

Craig Harcombe Lang O’Rourke

I finished the course with a clear vision of how to implement TPM in my own organisation. It was an excellent mix of practical and theoretical learning materials and techniques.

Clive Jones Faccenda Group

Exceeded my requirements. Great content delivered with enthusiasm, clear knowledge and experience in all subjects. Very good balance between classroom learning and practical shop floor exercises.

Craig Davies Coca Cola Enterprises

CHANGE

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BETTER CONTINUOUSIMPROVEMENT

KAIZENKAI ZEN

Masaaki Imai founded Kaizen Institute in 1985. Today, Kaizen Institute has more than 40 local offices, which apply Kaizen Lean methodologies in every business sector.

Kaizen is a Continuous Improvement philosophy with origins in Japan. Kaizen means changing for the better, every day, in every area of a company and involving every member of an organisation. The goal of Kaizen is to create competitive advantage to companies and public institutions through increased productivity, profitability and resource motivation, as well as eliminating waste, reducing production times and optimising equipment.

Kaizen is a daily use word in the business world, with increasing usage within all sectors of the economy.

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Kaizen College training is a program designed for all hierarchical levels and functions of an organisation. The goal of the program is to develop skills in continuous improvement, imparting knowledge through theory and practice, with simulation exercices and case studies. The knowledge transfer from Kaizen Institute enables every member of an organisation to contribute to the continuous improvement of an organisation’s results.

Kaizen Institute offers all their training courses in a public format as well as in house, customising the programs for every sector and tailoring them to specific client needs. The training program is practical, emphasising real life examples and work based scenarios, simulations and case study discussions. Most courses are held at a host site to enable delegates to see the theory in practice

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KAIZEN COLLEGE STRUCTURE

The goal of all organisations is to improve results continuously, hence adaptability to change is a crucial factor.

To face this challenge, promoting improvement behaviour and routines within the teams, as well as launching improvement projects supported by Kaizen Lean systems and tools is necessary. Developing a Governance structure to support and boost these improvements is just as important.

A cultural transformation is based on a set of principles and fundamental concepts which develop the Kaizen Lean mind-set and increase the belief and motivation for improvement.

The Kaizen College Training Program is divided into the Foundations, Culture and Tools Categories. Mastering these approaches will enable a gradual and effective implementation with guaranteed results.

WHAT IS YOUR CHALLENGE?

FOUNDATIONS & AWARENESS

To promote behaviours that will create continuous improvement routines

KAIZEN CULTURE

To improve processes in differing functions of the organisation

KAIZEN TOOLS

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12 Kaizen Lean Manufacturing

13 Kaizen Lean Logistics

14 Kaizen Lean Maintenance

15 Kaizen Lean Quality

16 Kaizen Lean Office & Services

17 Kaizen Lean Healthcare

18 Kaizen Lean Project Management

19 Kaizen Lean Product Development

20 Kaizen Lean A3 Problem Solving

08 Kaizen Foundations

FOUNDATIONS& AWARENESS TOOLS

KAIZEN COLLEGE

09 Daily Kaizen for Work Teams

10 Management Development Program

1 1 Continuous Improvement Cycles

CULTURE

KAIZEN FOUNDATIONSPROGRAM• Introduction to Kaizen and the Kaizen

Business System• Paradigms and resistance to change• Kaizen Lean principles• Added Value and the 7 kinds of Waste• Continuous Improvement key tools

• 5S

• Visual Management

• Standardisation

• 3C

• Gemba Walk• Simulation Exercises• Case Studies

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Kaizen Foundations is designed to raise awareness to the importance of continuous improvement, introducing attendees to the main concepts of Kaizen Lean.

MAIN BENEFITS• Understand Kaizen Foundations and their impact in organisations’ day-to-day;• Know how to identify and measure waste;• Learn the Kaizen principles and tools for problem solving and process improvement;• Observe how an Organisation can implement a Continuous Improvement System; • Successful case studies of implementing a Continuous Improvement Culture. 2 DAYS

Classroom Training and Gemba Walk

PROGRAM• Kaizen and Kaizen Business System• Kaizen Lean Principles• Kaizen Change Model• Daily Kaizen Planning• Teams Development Program

• Team Organisation

• Workplace Organisation

• Best Practice PDCA

• Improvement PDCA

• Deployment Roadmap• Simulation Exercises• Case Studies

Daily Kaizen for Work Teams addresses continuous improvement from a team management perspective. Its main goal is to understand that real Improvement is made up of daily improvements from a bottom-up.

MAIN BENEFITS• Prepare operational leaders to implement improvement techniques within their teams;• Develop leaders’ and members’ ability to improve their work areas and processes;• Create an Improvement Culture, starting with an organisation’s “Gemba”;• Successful case studies of implementing Kaizen in operational teams.

DAILY KAIZEN FOR WORK TEAMS

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2 DAYS

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PROGRAM• Kaizen and Kaizen Business System• Kaizen Lean Principles• Kaizen Change Model• Leaders’ Kaizen Model• Management Development Program

• Learning to see

• Setting targets

• Leading change

• Improving targets

• Simulation Exercises• Case Studies

Management Development Program shares best practices of continuous improvement for Management teams, in order to guarantee the good performance of operational teams.

MAIN BENEFITS• Improve management teams’ performance to reach Strategic Goals;• Learn which behaviours and management systems are necessary for a good

implementation and team monitoring;• Learn how to implement the Daily Kaizen model in management teams;• Successful case studies of implementing a Continuous Improvement Culture.

MANAGEMENT DEVELOPMENT PROGRAM

2 DAYSClassroom Training and Gemba Walk

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PROGRAM• Kaizen and Kaizen Business System• Kaizen Lean Principles• Kaizen Change Model• CI Planning

• Daily Kaizen & Leaders’ Kaizen Planning

• Value Stream Selection & Value Stream Mapping

• Hoshin Kanri

• CI Cycles• Mission Control

• Kaizen Events

• Events Closing & Value Review


Continuous Improvement Cycles teaches how to organise the 3 to 6 month Kaizen Project lifecycle methodology and review results at the end of each cycle.

MAIN BENEFITS• Learn how to plan Kaizen Events in 3 to 6 month cycles;• Know how to carry out Kaizen Events and use A3 Thinking; • Understand how to close Kaizen Events and measure results;• Know how Project Management is carried out in repetitive cycles within Benchmark companies;• Successful case studies of implementing a Continuous Improvement Culture.

CONTINUOUS IMPROVEMENT CYCLES


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KAIZEN LEAN MANUFACTURING

Kaizen Lean Manufacturing approaches operational efficiency in an industrial environment, allowing for productivity increases, cost reduction and shorter lead time within organisations.

MAIN BENEFITS• Know the Toyota Production System;• Understand the Lean Flow Management Model;• Prepare attendees to lead Improvement Projects in Production areas;• Learn how to define improvement solutions to optimise production and internal logistics;• Learn how to increase profitability of industrial processes; • Successful case studies of implementing Kaizen Lean in industry.

PROGRAM• Kaizen and Kaizen Business System• Added Value and the 7 Kinds of

Waste• Lean Flow Management• Creating Flow in Production

• Layout and Line Design

• Workstation Design

• Standard Work

• SMED

• Low Cost Automation

• Flow in Internal Logistics• Supermarkets

• Mizusumashi

• Synchronisation (Kanban and Junjo)

• Levelling

• Internal Pull Planning

• Simulation Exercises • Case Studies


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KAIZEN LEAN LOGISTICS

Kaizen Lean Logistics teaches how to optimise logistics operations, which will contribute to increasing storage process efficiency and transport profitability.

MAIN BENEFITS• Identify and measure waste in storage facilities;• Understand the impact of applying Kaizen Tools in storage facility operations;• Get to know different storage solutions and respective advantages and disadvantages;• Know how to create flow in storage and transport logistic operations;• Define key indicators and measurement methods for storage facilities’ performance;• Successful case studies of implementing Kaizen Lean in storage facilities and transportation.

PROGRAM• Kaizen and Kaizen Business System• Added Value and the 7 kinds of Waste• Lean Flow Management• External Logistics Flow

• Warehouse Design

• Milkrun

• Reception and storage

• Picking and Dispatch

• External Pull Planning



KAIZEN LEAN MAINTENANCE

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PROGRAM• Kaizen and Kaizen Business System • Total Productive Maintenance Model

• Kobetsu Kaizen

• Autonomous Maintenance

• Planned Maintenance

• Equipment Training

• Early Equipment Management

• Quality

• Safety and Environment

• Kaizen Office

• The 7 MUDA (wastes) applied to equipment

• Machine 5S• Maintenance Scorecard• Daily Kaizen in Maintenance

Kaizen Lean Maintenance teaches how to effectively manage maintenance teams and boost equipment efficiency and maintenance.

MAIN BENEFITS• Understand the potential of implementing Kaizen Lean in Equipment and Plant Maintenance;• Know how to apply Kaizen methods to improve equipment efficiency, employee involvement,

increase equipment lifespan, reduce maintenance costs and eliminate waste (Muda);• Know principles and actions to get to 0 accidents, 0 losses, 0 flaws and 0 damage• Successful case studies of implementing Kaizen Lean in maintenance warehouses and

transportation.2 DAYS


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KAIZEN LEAN QUALITYPROGRAM• Kaizen and Kaizen Business System• Added Value and Waste in Quality• 7 Kinds of Waste in Quality• Total Quality Control Model

• Improvement Cycle vs Standardisation Cycle

(PDCA/SDCA)

• Methods of Structured Problem Solving

• Differential Analysis

• Poka-Yoke (Anti-Error Systems)

• Autonomous Quality

• 6 Sigma in a Kaizen Lean perspective

• Case Studies

Kaizen Lean Quality helps develop methods of effective quality improvement which bring organisations financial gains.

MAIN BENEFITS• Understand the role of quality in a continuous improvement strategy;• Learn how to develop a zero faults strategy;• Learn the most used methods of quality improvement;• Know how to select the most adequate tool for each type of problem;• Successful case studies of implementing Kaizen Lean in equipment maintenance. 2 DAYS


KAIZEN LEAN OFFICE & SERVICES

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PROGRAM• Kaizen and Kaizen Business System• Added Value and the 7 kinds of Waste• Lean Service Management• Office Flow and Logistics

• Process Mapping

• Standard Work

• Automation

• Knowledge Management

• Pacing and Pull Planning

• Quality & Customer Experience• Structured Problem Solving

• Service Quality Control

• Auto-Quality Matrix

• Client Experience Mapping

• Client Environment Design

• Client Interaction Improvement and Follow-Up

• Process Management• Archive and Stock Management

• Work and Resources Planning


Kaizen Lean Office & Services teaches continuous improvement tools for Services and Support Areas, increasing productivity and focus on the customer, as well as decreasing mistakes and response times.

MAIN BENEFITS• Understand the importance of continuous improvement for an excellent performance in

Services and Support Areas;• Prepare attendees to lead Improvement Projects in Services;• Enable attendees to design and implement solutions to improve transactional processes;• Successful Case Studies of implementing Kaizen Lean in services. 2 DAYS


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KAIZEN HOSPITALITY

Kaizen Hospitality helps develop continuous improvement tools for Hospitality, increasing productivity and focus on the customer experience, as well as decreasing mistakes and response times.


Hospitality;• Prepare attendees to lead Improvement Projects in Hospitality;• Enable attendees to design and implement solutions to improve hospitality processes;• Successful Case Studies of implementing Kaizen Lean in hospitality. 2 DAYS


PROGRAM• Kaizen and Kaizen Business System• Added Value and the 7 kinds of Waste• Lean Service Management• Hospitality Flow and Logistics

• Process Mapping

• Standard Work

• Automation












KAIZEN PUBLIC SECTOR

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Kaizen Public Sector instructs continuous improvement tools for the Public Sector, increasing efficiency and focus on the citizens, as well as decreasing mistakes and waiting times.

MAIN BENEFITS• Understand the importance and impact of continuous improvement in the Public Sector;• Learn how to improve the quality and efficiency of Public Sector Services;• Understand strategies of increasing added value for the citizen;• Successful Case Studies of implementing Kaizen Lean in the public sector.


PROGRAM• Kaizen and Kaizen Business System• Added Value and the 7 kinds of Waste• Lean Service Management• Public Sector Flow and Logistics

• Process Mapping

• Standard Work

• Automation












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KAIZEN RETAIL

Kaizen Retail teaches continuous improvement tools for Retail, increasing productivity and focus on the customer experience, as well as decreasing mistakes and response times.


Retail;• Prepare attendees to lead improvement Projects in Retail;• Enable attendees to design and implement solutions to improve retail processes;• Successful Case Studies of implementing Kaizen Lean in retail. 2 DAYS


PROGRAM• Kaizen and Kaizen Business System• Added Value and the 7 kinds of Waste• Lean Service Management• Retail Flow and Logistics

• Process Mapping

• Standard Work

• Automation












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KAIZEN LEAN HEALTHCAREPROGRAM• Kaizen and Kaizen Business System• Paradigms and Resistance to Change• Added Value and the 7 kinds of Waste• Healthcare Flow and Logistics

• Process Mapping

• Standard Work

• Automation

• SMED


• Quality & Costumer Experience• Structured Problem Solving


• Customer Experience Mapping


• Improvement of Client Interaction and Follow-up


• Resource and Work Planning


Kaizen Lean Healthcare teaches continuous improvement tools for Healthcare, increasing efficiency and the focus on the patient, as well as decreasing mistakes and waiting times.

MAIN BENEFITS• Understand the importance and impact of continuous improvement in Healthcare;• Learn how to improve the quality and efficiency of Healthcare Services;• Understand strategies of increasing added value for the patient;• Successful Case Studies of implementing Kaizen in healthcare.


KAIZEN LEAN PROJECT MANAGEMENT

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PROGRAM• Kaizen and Kaizen Business System• Transition from a Traditional

Management Method to Lean Project Management

• Principles of Lean Project Management• Project Release

• Project Design (Milestones, Stage Gate

Models)

• Project Mapping

• Last Planner System

• Obeya Control

• Risk Kanban

• Project Standards

• Project Management Practical Exercises

• Case StudiesKaizen Lean Project Management focuses on managing projects from a continuous improvement perspective, teaching attendees how to increase quality and profitability, whilst shortening project lead-times.

MAIN BENEFITS• Understand the role of continuous improvement in the success of a project;• Learn the Toyota method of project management - achieve higher quality results, reduce

costs, decrease lead time and time to market;• Learn strategic, tactical and operational tools for better project management;• Successful Case Studies of implementing Kaizen Lean in Project Management. 2 DAYS


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KAIZEN LEAN PRODUCT DEVELOPMENT PROGRAM• Kaizen and Kaizen Business System• Set Based Engineering techniques:

• Customer Interests Boards

• Feasibility Planning

• Learning Cycles

• Integration Events

• Lean Capacity Management techniques• 3P techniques: Production Preparation

Process• Simulation Exercises• Case Studies

Kaizen Lean Product Development teaches how to develop superior quality products (Best Sellers) whilst respecting budget and shortening time frames (Time to Market).

MAIN BENEFITS• Improve Quality and efficiency in Conceptual Design of New Products using the new Set

Based Engineering paradigm;• Learn how to design Products and Processes with Lean principles applied at Toyota (LCM

and 3P techniques);• A new Product Development Paradigm, the IDM Model: Innovation & Development Management;• Successful case studies of implementing Kaizen Lean in product development.


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KAIZEN LEAN A3 PROBLEM SOLVING PROGRAM• Kaizen and Kaizen Business System• Kobetsu Kaizen and the 8 Step

Structural Problem Solving A3 Process• Step 1: Clarify the problem

• Step 2: Breakdown the problem

• Step 3: Set the target

• Step 4: Analyse root cause

• Step 5: Define countermeasures

• Step 6: Implement countermeasures

• Step 7: Monitor results and process

• Step 8: Standardise and share success

• The A3 Report• Practical Exercises with work based

problems

Kaizen Lean A3 Problem Solving focuses on delivering tools to support and drive structured problem resolution in all areas and sectors of organisations, teaching with practical, work centred examples and exercises.

MAIN BENEFITS• Learn how to apply the A3 Problem Solving process across all activities;• Be able to carry out the 8 Step Practical Problem Solving Process independently, applying it

in structured problem solving.

2 DAYSClassroom Training

Kaizen Institute Malta | [email protected] | mt.kaizen.com

kaizen college - intrexx xtreme · the kaizen college training program provides practical training...

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