Continuous Improvement Mastery Through PDCA, Lean & TPM in Action

This comprehensive 3-day course offers an in-depth exploration of the PDCA Cycle, Lean Manufacturing, Total Productive Maintenance (TPM), and Visual Factory principles, designed to give participants a robust understanding of these powerful methodologies and how they can be effectively implemented to drive continuous improvement in manufacturing environments.

Description

Throughout the course, you’ll engage with the PDCA Cycle, learning not just the theory behind it, but how to apply each step — Plan, Do, Check, and Act — to solve problems, eliminate waste, and streamline operations. We'll delve into Lean principles, such as Value Stream Mapping, 5S, and Kaizen, teaching you how to identify and eliminate inefficiencies, reduce downtime, and enhance productivity across the organization. Additionally, you'll explore Total Productive Maintenance (TPM), a system focused on maximizing equipment effectiveness and reliability, and discover the transformative power of Visual Factory concepts to improve communication, transparency, and team accountability.

What the Class Experience Will Be Like:

· Interactive Learning: Expect an engaging classroom experience with plenty of discussion around the real-world application of concepts.

· Practical Application: This course focuses on practical knowledge that can be applied immediately in your workplace.

· Tools & Techniques: You’ll learn key Lean tools like Kaizen, Root Cause Analysis, Kanban, and 5S, as well as how to integrate these with PDCA and TPM for maximum impact. By the end of the course, you’ll have a complete toolkit for implementing these strategies in your organization.

Course Duration: 3 days

This course is perfect for professionals looking to deepen their understanding of Lean Manufacturing, Total Productive Maintenance, and Continuous Improvement. Whether

you're a manager, team leader, or process improvement professional, this course will provide you with the knowledge and confidence to implement these strategies and drive lasting change in your organization.

 

Outline

Introduction to Continuous Improvement

· Continuous Improvement Overview

· PDCA Cycle and Its Importance

· Lean Manufacturing Overview

· Key Lean Concepts: Waste (Muda), Flow (Muri), and Variability (Mura)

PDCA Cycle – In-Depth Breakdown

· Plan: Problem Identification and Solution Planning

o CTQ for Objective and Subjective Metrics

o What Why How Drills

o Root Cause Tree (RCT)

o Fault Tree Analysis (FTA)

o 5 Why Exercises

o Pareto Analysis

o XY Matrix

o DFMEA & PFMEA

o A3 Problem Solving

· Do: Small-Scale Implementation

o Risk Identification

o Interrelationship Digraphs

· Check: Measurement and Evaluation

o Control Charts SPC

o Measurement Systems Analysis (MSA)

o Precision vs Accuracy

o Scatter Diagrams for Correlation and Causation

· Act: Standardizing and Scaling Improvements

o Building Product/Process Vision (Technique)

o Kano Analysis

Lean Manufacturing Fundamentals

· Value Stream Mapping (VSM)

· 5S Methodology

· Kaizen Principles

· Kanban Systems

o Types of Kanban Systems

o Kanban Boards and Cards

o Understanding WIP Limits

· The Role of Lean in Eliminating Waste

Total Productive Maintenance (TPM)

· Introduction to TPM

· The 8 Pillars of TPM

· Autonomous Maintenance

· Overall Equipment Effectiveness (OEE)

· Reducing Downtime through TPM

Lean Tools for Waste Reduction

· Value Stream Mapping (VSM) for Waste Identification

· Poka-Yoke (Error-Proofing)

· Kaizen for Continuous Improvement

Standardizing and Sustaining Improvements

· Developing Standardized Work Procedures

· Monitoring and Sustaining Lean Gains

· Avoiding Backsliding: Audits and Metrics

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