practices. Euclides Coimbra Senior Partner & Managing Director - Kaizen Institute Western Europe

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1 KAIZEN COLLEGE

2 2 practices. 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 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 Coimbra Senior Partner & Managing Director - Kaizen Institute Western Europe

3 Craig Davies Coca Cola Enterprises 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. 3 Craig Harcombe Lang O Rourke 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. Clive Jones Faccenda Group 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.

4 4 Masaaki Imai founded Kaizen Institute in 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. KAI CHANGE + = ZEN BETTER KAIZEN CONTINUOUS IMPROVEMENT Kaizen is a daily use word in the business world, with increasing usage within all sectors of the economy.

5 5 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

6 KAIZEN COLLEGE STRUCTURE WHAT IS YOUR CHALLENGE? To promote behaviours that will create continuous improvement routines To improve processes in differing functions of the organisation 6 KAIZEN CULTURE KAIZEN TOOLS FOUNDATIONS & AWARENESS 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.

7 KAIZEN COLLEGE 7 FOUNDATIONS & AWARENESS CULTURE TOOLS 08 Kaizen Foundations 09 Daily Kaizen for Work Teams 10 Management Development Program 11 Continuous Improvement Cycles 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

8 KAIZEN FOUNDATIONS 8 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 Kaizen Foundations is designed to raise awareness to the importance of continuous improvement, introducing attendees to the main concepts of Kaizen Lean. 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.

9 DAILY KAIZEN FOR WORK TEAMS 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 9 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. 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.

10 MANAGEMENT DEVELOPMENT 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 10 Management Development Program shares best practices of continuous improvement for Management teams, in order to guarantee the good performance of operational teams. 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.

11 CONTINUOUS IMPROVEMENT CYCLES 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 Simulation Exercises Case Studies 11 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. 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.

12 KAIZEN LEAN MANUFACTURING 12 Kaizen Lean Manufacturing approaches operational efficiency in an industrial environment, allowing for productivity increases, cost reduction and shorter lead time within organisations. 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 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.

13 KAIZEN LEAN LOGISTICS 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 Simulation Exercises Case Studies 13 Kaizen Lean Logistics teaches how to optimise logistics operations, which will contribute to increasing storage process efficiency and transport profitability. 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.

14 KAIZEN LEAN MAINTENANCE 14 Kaizen Lean Maintenance teaches how to effectively manage maintenance teams and boost equipment efficiency and maintenance. 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 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.

15 KAIZEN LEAN QUALITY 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 15 Kaizen Lean Quality helps develop methods of effective quality improvement which bring organisations financial gains. 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.

16 KAIZEN LEAN OFFICE & SERVICES 16 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. 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 Simulation Exercises Case Studies 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.

17 KAIZEN LEAN HEALTHCARE 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. Paradigms and Resistance to Change Added Value and the 7 kinds of Waste Healthcare Flow and Logistics Process Mapping Standard Work Automation SMED Knowledge Management Quality & Costumer Experience Structured Problem Solving Service Quality Control Customer Experience Mapping Client Environment Design Improvement of Client Interaction and Follow-up Process Management Archive and Stock Management Resource and Work Planning Simulation Exercises Case Studies 17 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.

18 KAIZEN LEAN PROJECT MANAGEMENT 18 Kaizen 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. 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 Studies 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.

19 KAIZEN LEAN PRODUCT DEVELOPMENT 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 19 Kaizen Lean Product Development teaches how to develop superior quality products (Best Sellers) whilst respecting budget and shortening time frames (Time to Market). 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.

20 KAIZEN LEAN A3 PROBLEM SOLVING 20 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. 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.

21 The journey of a thousand miles begins with one step Lao Tzu 21

22 Kaizen Institute UK +44 (0) uk.kaizen.com