1. Agenda: Lean Workshop – Rapid Site Assessment, Value Stream Mapping
Day 1 (8:00am – 5:00pm)
Introduction to Leadership team
Lean Leader module and System Kaizen Approach 1 hr
Rapid Site Assessment – Questionnaire and observation of core process steps of key profit
center.
Summary assessment and share findings with company principal (Laura Green)
Day 2 (8:00am – 5:00pm) Break for lunch 12 -1 – Maintenance Technicians - STD Work
Introduction of core teams to Exercise Lean Group
Installation and maintenance process overview
Code of conduct for workshop
Discussion of who is customer ( internal and external) requirements
Define project scope (which Service Value Stream)
Installation and maintenance standardize work
Define the current process with the core team
Establish standard work with flow chart and template that defines the major steps,
key points (safety note, critical note and quality note), reason for the key point and
photographic picture is possible.
Train participants in new standard
Test and validate wherever possible.
Evaluation workshops forms completed (continuous improvement for EL Group
Day 3 (8:00am – 5:00pm) Break for lunch 12 -1
Define the new product / process introduction elements to track
Develop / Review project plan for introduction (Gantt Chart) See steps below
o Step 1 Initiate Project
o Process Design
o Process Validation
o Launch Readiness Review (Documentation, Training, Materials,
Prepared by John F Petak www.exerciselean.com 864.363.0984
2. o Equipment)
o Step 2
Analyze Gaps and Failures in the Current Process.
Brainstorm Solutions
o Step 3
o Design New Process using VSM with and determine targets
o
o Step 4 Install New Process.
Layout Production Area using 5S from the Start
Establish Information and Material Flows using Visual Management Only (Launch
Board/Job Status Board)
Train Staff on Work Flows
Conduct Rehearsals
o Step 5
Run and Debug New Process
1. Daily Meetings
2. PDCA Action Plan
3. Institutionalize Processes
o Step 5 Verification
Develop VSM for new process based on what is known
Define process flow through flow chart and spaghetti diagram
Define targets for Knowledge Management (knowledge collection)
Define how standard work will be formatted (Procedure / flow chart / etc)
Evaluation workshops forms completed (continuous improvement for EL Group)
Day 4 (8:00am – 5:00pm) Break for lunch 12 -1
Develop an action plan that covers task, sequence, priority, resource and time scale Gantt
Keep the timescales realistic (30 – 60 days)
Integrate value stream plan with identified actions from the matrix of KAIZEN Systems
Evaluation workshops forms completed (continuous improvement for EL Group)
Prepared by John F Petak www.exerciselean.com 864.363.0984
3. Day 5 (8:00am – 5:00pm) Break for lunch 12 -1
Summarize the week
Complete business drivers on metrics
Finalize Plan Do Check Act worksheet
Complete A3 Report
Prepare workshop participants for management review
Management Review
Follow up with management team
Evaluation workshops forms completed (continuous improvement for EL Group
Departure
Prepared by John F Petak www.exerciselean.com 864.363.0984