Contents Outline

Module One: Getting Started    4

Workshop Objectives    4

Pre-Assignment Review    5

Module Two: Understanding Lean    6

About Six Sigma    6

About Lean    7

History behind Lean    8

Toyota Production Systems    8

The Toyota Precepts    9

Module Three: Liker’s Toyota Way    10

Philosophy    10

Process    11

People and Partners    12

Problem Solving    13

Module Four: The TPS House    15

The Goals of TPS    15

The First Pillar: Just In Time (JIT)    16

The Second Pillar: Jidoka (Error-Free Production)    16

Kaizen (Continuous Improvement)    17

The Foundation of the House    18

Module Five: The Five Principles of Lean Business    19

Value    19

Value Stream    20

Flow    20

Pull    20

Seek Perfection    21

Module Six: The First Improvement Concept (Value)    22

Basic Characteristics    22

Satisfiers    23

Delighters    23

Applying the Kano Model    24

Module Seven: The Second Improvement Concept (Waste)    25

Muda    25

Mura    26

Muri    26

The New Wastes    26

Module Eight: The Third Improvement Concept (Variation)    27

Common Cause    27

Special Cause    28

Tampering    28

Structural    28

Module Nine: The Fourth Improvement Concept (Complexity)    29

What is Complexity?    29

What Causes Complexity?    29

How to Simplify?    30

Module Ten: The Fifth Improvement Concept (Continuous Improvement)    31

The PDSA Cycle (Plan, Do, Study, Act)    31

The DMAIC Method    32

Module Eleven: The Improvement Toolkit    33

Gemba    33

Genchi Genbutsu    34

Womack’s Principle    34

Kaizen    34

A Roadmap for Implementation    35

Module Twelve: Wrapping Up    37

Words from the Wise    37