Implementation of Kaizen in the Production Floor

Course Code: MRMC 132

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Course Sector:

Maintenance & Reliability Management

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Introduction

Training course introducion / brief

This training program is designed to help professionals gain an in-depth understanding of Kaizen continuous improvement process. This training program will get participants to learn practical approaches and applications of the system rather than just listening for higher retention of concepts and theory. Exercises, practical implementations in the production floor, and case studies will also be integrated into the training program to demonstrate and bring to life the concepts being taught.

Gain a comprehensive understanding of the Kaizen concept and principles.
Master Using Kaizen tools.
Design a Kaizen Plan in the production floor.
Master implementing Kaizen in the production processes.
Apply and measure Kaizen in the production floor.

Introduction to Kaizen:

The concept of continuous improvement management.
Understand KAIZEN in Japanese.
Development History of the Japanese strategy for continuous improvement (KAIZEN).
Kaizen benefits for production processes “Case Studies”.
How does the Japanese KAIZEN strategy work?
KAIZEN's relationship with the DEMING CYCLE.
A comparison between KAIZEN and the rest of the continuous improvement processes (TQM, TPM, QC, SIX SIGMA).
Strengths of the KAIZEN program.

Your Guide to understand Kaizen Tools:

Check Sheet.
Pareto Chart.
7QC Tools and their Application.
Histogram.
Scatter Diagram.
Process Map.
Cause and Effect Diagram.
Process Map.
Control Chart.
Root-cause analysis.
Fishbone Method.
(ISHIKAWA).
Five-question style.
(5 WHYS).
Optimization-based processing method.
Workshop.

Developing Kaizen Strategy:

Introduction of Kaizen Strategy.
How to Plan for a Kaizen Continuous Improvement Programme?
Design the Kaizen Culture.
Developing a Kaizen Roadmap.
Planning and Organising Effective Kaizen Events.
Selecting and Handling Projects.
Kaizen Teams formation strategy.
The Roles of Team Members.
Performance Metrics.
Understand Kaizen PDCA.

Mapping of Process and Value Stream

Process Mapping Overview.
Understand Value Stream Mapping Principles and Methodology.
Mapping Tools and Symbols.
Using Process Maps.
Understand and apply Value Stream Maps.
How to Prioritise and Select Kaizen Projects.
Strategies of Developing Project Charter and Project Plan.

Implementing of Kaizen Project:

Identify the Kaizen Project.
The structure and steps of Kaizen Project.
Prepare the Kaizen Event.
Understanding Workplace Kaizen.
Map Current State for the Kaizen Project.
Identify Areas for Improvement.
Map Future State.
Cost and Benefit Analysis of Projects.
Implementing Future State Improvements.
Post-Project Review and Follow-Up.
Identify Further Areas for Improvement/Skills Development.
Project Presentation.

Practical Application: Implementation of Kaizen in the production floor:

Applied tools for the continuous improvement process of according to the KAIZEN strategy methodology
How can we eliminate overproduction?
How can we improve manufacturing quality?
How can we make manufacturing more efficient?
How can we remove unneeded steps in manufacturing?
How can we eliminate errors in the final product?
Practical applications on industrial processes using kaizen.
Practical applications on office and administrative operations using kaizen.

Boost certificate of completion

BOOST's Professional Attendance Certificate “BPAC” is always given to the delegates after completing the training course, and depends on their attendance of the program at a rate of no less than 80%, besides their active participation and engagement during the program sessions.

ENDORSED EDUCATION PROVIDER

Flexible deadlines

Customized dates accordance to your schedule

Shareable Certificate

Earn certificate upon completion

COURSE METHODOLOGY

Our Training programs are implemented by combining the participants' academic knowledge and practical practice (30% theoretical / 70% practical activities).

At The end of the training program, Participants are involved in practical workshop to show their skills in applying what they were trained for. A detailed report is submitted to each participant and the training department in the organization on the results of the participant's performance and the return on training. Our programs focus on exercises, case studies, and individual and group presentations.

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TRAINING COURSE: Implementation of Kaizen in the Production Floor