Continual Improvement and Lean Kaizen


Training Overview:

This training program is designed to teach the participants the tools, techniques, and management concepts of Total Quality Management (TQM) with a focus on the practice of “LEAN Kaizen”.
Kaizen is a management concept attributed to Masaaki Imai. In his book “Kaizen: The key to Japan’s competitive success”, Imai describes Kaizen as an “ongoing improvement involving everyone, including both managers and workers. The Kaizen philosophy assumes that our way of life – be it in our working life, our social life, or our home life – deserves to be constantly improved.”
Kaizen also referred to as “continual improvement”, is a central pillar of the Toyota Production System and its success as the world’s leading automobile manufacturer.
TQM, on the other hand, is a business strategy committed to producing a quality product or service. It has become one of the main strategies adopted by many successful companies to improve performance, productivity, and profitability. Kaizen is also a key component of TQM.

Training Objective:

At the end of the training, program participants are expected to have a clear idea of how TQM and Kaizen can be applied to improve the performance of their departments.

Module Overview:

· The LEAN Kaizen Concept
· The History of TQM
· The Quality Gurus
· Deming’s Quality Cycle Model
· The Five Pillars of TQM
· Customer Satisfaction
· Leadership and Teamwork
· Total Commitment
· Training and Continuous Improvement
· Measurement of KPIs
· Mapping your Business Model
· Creating a Customer Focused Operation
· Creating a Data-Driven Organization
· Introduction to the main quality improvement strategies
· Lean

The Tools of Process Improvement

· Process Mapping
· Value Stream Mapping
· Takt Time Analysis
· KANO Analysis
· Listening to the Voice of the Customer
· Kanban
· RMP Brainstorming Technique
· Affinity Maps

The 7 Basic QC Tools

· The Pareto Diagram
· The Fishbone Diagram (Cause and Effect Diagram)
· The Graphs
· The Checksheet
· The Histogram
· The Scatter Diagrams
· The Control Charts
· Poka-Yoke (Mistake Proofing)
· PDCA (Plan, Do, Check and Act)
· Applying Continual improvement through Kaizen (Continuous Improvement)
· Creating your Key Performance Indicators (KPIs)
· Creating your Improvement Report (Toyota A3 Report Format)


· Classroom training
· Group discussion
· Practical Examples
· Exercises, Q&A session and examination
· Well defined course material hardcopy to recall during implementation

Who should attend?

· Managers
· Supervisors
· Process Engineers
· Team Leaders
· Manufacturing Specialists