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Course 3: Continuous Process Improvement: Identifying & Eliminating Waste 125

This course reviews the fundamentals of waste — everything from the types of waste to recognizing abnormality — as well as some of the tools used to identify waste. Review the importance of stability to identify the root cause of waste. And, review the differences between kaizen (continuous improvement) and kaikaku (radical change), and why both are useful.

Course Outline
  • Objectives
  • Barriers to Flow
  • The Seven Wastes
  • Stability
  • Tools for Creating Stability
  • 5S
  • Total Productive Maintenance
  • The Six Big Losses
  • Standardization
  • Recognizing Abnormality
  • Addressing Problems and Preventing Defects
  • Jidoka
  • A3 Reports
  • Plan-Do-Check-Act
  • Using DMAIC for Process Improvement
  • Kaizen vs. Kaikaku
  • Gemba
  • Summary

Course Objectives
  • Describe the main barriers to flow.
  • Describe the seven wastes.
  • Define stability.
  • List tools for creating stability.
  • Describe the 5S method of organization.
  • Describe total productive maintenance.
  • List the six big losses in maintenance.
  • Describe standardized work.
  • Describe andons as a tool for recognizing abnormality.
  • Describe methods for addressing problems and preventing defects.
  • Define jidoka.
  • Describe A3 problem solving reports.
  • Describe the Plan-Do-Check-Act cycle.
  • Describe the DMAIC process.
  • Distinguish between kaizen and kaikaku.
  • Describe gemba.