Lean Management

  1. Core Lean Tools and Methodologies
    1. Value Stream Mapping (VSM)
      1. VSM Fundamentals
        1. Purpose and Objectives
          1. Scope Definition
            1. Team Formation
              1. Data Requirements
              2. Current State Mapping
                1. Process Observation
                  1. Data Collection
                    1. Mapping Symbols
                      1. Information Flow
                        1. Material Flow
                          1. Timeline Development
                          2. Analysis and Waste Identification
                            1. Process Metrics
                              1. Bottleneck Analysis
                                1. Waste Quantification
                                  1. Improvement Opportunities
                                  2. Future State Design
                                    1. Improvement Prioritization
                                      1. Target Metrics
                                        1. Process Redesign
                                          1. Implementation Planning
                                          2. Action Plan Development
                                            1. Project Planning
                                              1. Resource Allocation
                                                1. Timeline Creation
                                                  1. Responsibility Assignment
                                                2. 5S Workplace Organization
                                                  1. 5S Overview
                                                    1. Philosophy and Benefits
                                                      1. Implementation Approach
                                                        1. Sustainability Factors
                                                        2. Seiri (Sort)
                                                          1. Item Classification
                                                            1. Red Tag Process
                                                              1. Disposal Methods
                                                                1. Decision Criteria
                                                                2. Seiton (Set in Order)
                                                                  1. Organization Principles
                                                                    1. Visual Management
                                                                      1. Location Designation
                                                                        1. Accessibility Optimization
                                                                        2. Seiso (Shine)
                                                                          1. Cleaning Standards
                                                                            1. Inspection Procedures
                                                                              1. Maintenance Integration
                                                                                1. Problem Identification
                                                                                2. Seiketsu (Standardize)
                                                                                  1. Standard Development
                                                                                    1. Documentation Methods
                                                                                      1. Training Programs
                                                                                        1. Audit Systems
                                                                                        2. Shitsuke (Sustain)
                                                                                          1. Habit Formation
                                                                                            1. Discipline Maintenance
                                                                                              1. Continuous Training
                                                                                                1. Performance Monitoring
                                                                                              2. Kaizen: Continuous Improvement
                                                                                                1. Kaizen Philosophy
                                                                                                  1. Improvement Mindset
                                                                                                    1. Employee Participation
                                                                                                      1. Small Step Approach
                                                                                                        1. Systematic Method
                                                                                                        2. Kaizen Events
                                                                                                          1. Event Planning
                                                                                                            1. Team Selection
                                                                                                              1. Facilitation Techniques
                                                                                                                1. Implementation Process
                                                                                                                  1. Follow-up Activities
                                                                                                                  2. PDCA Cycle
                                                                                                                    1. Plan Phase
                                                                                                                      1. Problem Definition
                                                                                                                        1. Root Cause Analysis
                                                                                                                          1. Solution Development
                                                                                                                            1. Implementation Planning
                                                                                                                            2. Do Phase
                                                                                                                              1. Pilot Implementation
                                                                                                                                1. Data Collection
                                                                                                                                  1. Process Monitoring
                                                                                                                                    1. Issue Resolution
                                                                                                                                    2. Check Phase
                                                                                                                                      1. Results Analysis
                                                                                                                                        1. Performance Measurement
                                                                                                                                          1. Success Evaluation
                                                                                                                                            1. Learning Capture
                                                                                                                                            2. Act Phase
                                                                                                                                              1. Standardization
                                                                                                                                                1. Training Update
                                                                                                                                                  1. Horizontal Deployment
                                                                                                                                                    1. Next Cycle Planning
                                                                                                                                                  2. Gemba Management
                                                                                                                                                    1. Gemba Walk Principles
                                                                                                                                                      1. Observation Techniques
                                                                                                                                                        1. Employee Engagement
                                                                                                                                                          1. Problem Identification
                                                                                                                                                            1. Coaching Opportunities
                                                                                                                                                          2. Just-In-Time (JIT) Production
                                                                                                                                                            1. JIT Principles
                                                                                                                                                              1. Demand-Pull Production
                                                                                                                                                                1. Inventory Minimization
                                                                                                                                                                  1. Quality at Source
                                                                                                                                                                    1. Supplier Integration
                                                                                                                                                                    2. Takt Time
                                                                                                                                                                      1. Calculation Methods
                                                                                                                                                                        1. Application Techniques
                                                                                                                                                                          1. Workload Balancing
                                                                                                                                                                            1. Capacity Planning
                                                                                                                                                                            2. Flow Implementation
                                                                                                                                                                              1. Cell Design
                                                                                                                                                                                1. Layout Optimization
                                                                                                                                                                                  1. Batch Size Reduction
                                                                                                                                                                                    1. Setup Time Reduction
                                                                                                                                                                                    2. Supplier Relationships
                                                                                                                                                                                      1. Partnership Development
                                                                                                                                                                                        1. Quality Agreements
                                                                                                                                                                                          1. Delivery Scheduling
                                                                                                                                                                                            1. Communication Systems
                                                                                                                                                                                          2. Kanban Systems
                                                                                                                                                                                            1. Kanban Fundamentals
                                                                                                                                                                                              1. Visual Management Principles
                                                                                                                                                                                                1. Signal-Based Control
                                                                                                                                                                                                  1. Pull System Implementation
                                                                                                                                                                                                    1. Flow Optimization
                                                                                                                                                                                                    2. Kanban Types
                                                                                                                                                                                                      1. Production Kanban
                                                                                                                                                                                                        1. Withdrawal Kanban
                                                                                                                                                                                                          1. Supplier Kanban
                                                                                                                                                                                                            1. Emergency Kanban
                                                                                                                                                                                                            2. Kanban Design
                                                                                                                                                                                                              1. Card Design Elements
                                                                                                                                                                                                                1. Information Requirements
                                                                                                                                                                                                                  1. Quantity Determination
                                                                                                                                                                                                                    1. Routing Instructions
                                                                                                                                                                                                                    2. Work-in-Progress (WIP) Management
                                                                                                                                                                                                                      1. WIP Limit Setting
                                                                                                                                                                                                                        1. Bottleneck Management
                                                                                                                                                                                                                          1. Flow Monitoring
                                                                                                                                                                                                                            1. Capacity Balancing
                                                                                                                                                                                                                            2. Kanban Boards
                                                                                                                                                                                                                              1. Physical Board Design
                                                                                                                                                                                                                                1. Digital Tools
                                                                                                                                                                                                                                  1. Status Tracking
                                                                                                                                                                                                                                    1. Performance Metrics
                                                                                                                                                                                                                                  2. Jidoka: Autonomation
                                                                                                                                                                                                                                    1. Jidoka Principles
                                                                                                                                                                                                                                      1. Automation with Human Intelligence
                                                                                                                                                                                                                                        1. Quality at Source
                                                                                                                                                                                                                                          1. Problem Detection
                                                                                                                                                                                                                                            1. Immediate Response
                                                                                                                                                                                                                                            2. Andon Systems
                                                                                                                                                                                                                                              1. Visual Signals
                                                                                                                                                                                                                                                1. Audio Alerts
                                                                                                                                                                                                                                                  1. Escalation Procedures
                                                                                                                                                                                                                                                    1. Response Protocols
                                                                                                                                                                                                                                                    2. Line Stop Authority
                                                                                                                                                                                                                                                      1. Employee Empowerment
                                                                                                                                                                                                                                                        1. Stop Criteria
                                                                                                                                                                                                                                                          1. Problem Resolution
                                                                                                                                                                                                                                                            1. Restart Procedures
                                                                                                                                                                                                                                                            2. Human-Machine Separation
                                                                                                                                                                                                                                                              1. Task Allocation
                                                                                                                                                                                                                                                                1. Skill Requirements
                                                                                                                                                                                                                                                                  1. Safety Considerations
                                                                                                                                                                                                                                                                    1. Efficiency Optimization
                                                                                                                                                                                                                                                                  2. Poka-Yoke: Error-Proofing
                                                                                                                                                                                                                                                                    1. Error-Proofing Principles
                                                                                                                                                                                                                                                                      1. Mistake Prevention
                                                                                                                                                                                                                                                                        1. Detection Methods
                                                                                                                                                                                                                                                                          1. Correction Mechanisms
                                                                                                                                                                                                                                                                            1. Design Integration
                                                                                                                                                                                                                                                                            2. Poka-Yoke Types
                                                                                                                                                                                                                                                                              1. Control Methods
                                                                                                                                                                                                                                                                                1. Warning Methods
                                                                                                                                                                                                                                                                                  1. Shutdown Methods
                                                                                                                                                                                                                                                                                    1. Contact Methods
                                                                                                                                                                                                                                                                                      1. Fixed-Value Methods
                                                                                                                                                                                                                                                                                        1. Motion-Step Methods
                                                                                                                                                                                                                                                                                        2. Implementation Process
                                                                                                                                                                                                                                                                                          1. Error Analysis
                                                                                                                                                                                                                                                                                            1. Solution Design
                                                                                                                                                                                                                                                                                              1. Testing and Validation
                                                                                                                                                                                                                                                                                                1. Standardization
                                                                                                                                                                                                                                                                                                2. Device Categories
                                                                                                                                                                                                                                                                                                  1. Mechanical Devices
                                                                                                                                                                                                                                                                                                    1. Electrical Systems
                                                                                                                                                                                                                                                                                                      1. Software Solutions
                                                                                                                                                                                                                                                                                                        1. Procedural Methods
                                                                                                                                                                                                                                                                                                      2. Heijunka: Production Leveling
                                                                                                                                                                                                                                                                                                        1. Leveling Principles
                                                                                                                                                                                                                                                                                                          1. Volume Smoothing
                                                                                                                                                                                                                                                                                                            1. Mix Leveling
                                                                                                                                                                                                                                                                                                              1. Resource Optimization
                                                                                                                                                                                                                                                                                                                1. Variation Reduction
                                                                                                                                                                                                                                                                                                                2. Heijunka Box
                                                                                                                                                                                                                                                                                                                  1. Design Principles
                                                                                                                                                                                                                                                                                                                    1. Scheduling Methods
                                                                                                                                                                                                                                                                                                                      1. Visual Management
                                                                                                                                                                                                                                                                                                                        1. Flexibility Maintenance
                                                                                                                                                                                                                                                                                                                        2. Implementation Strategies
                                                                                                                                                                                                                                                                                                                          1. Demand Analysis
                                                                                                                                                                                                                                                                                                                            1. Capacity Planning
                                                                                                                                                                                                                                                                                                                              1. Schedule Development
                                                                                                                                                                                                                                                                                                                                1. Performance Monitoring
                                                                                                                                                                                                                                                                                                                              2. Standardized Work
                                                                                                                                                                                                                                                                                                                                1. Standardization Principles
                                                                                                                                                                                                                                                                                                                                  1. Best Practice Documentation
                                                                                                                                                                                                                                                                                                                                    1. Consistency Achievement
                                                                                                                                                                                                                                                                                                                                      1. Training Foundation
                                                                                                                                                                                                                                                                                                                                        1. Improvement Baseline
                                                                                                                                                                                                                                                                                                                                        2. Standard Work Elements
                                                                                                                                                                                                                                                                                                                                          1. Takt Time Integration
                                                                                                                                                                                                                                                                                                                                            1. Work Sequence Definition
                                                                                                                                                                                                                                                                                                                                              1. Standard Inventory Levels
                                                                                                                                                                                                                                                                                                                                                1. Quality Checkpoints
                                                                                                                                                                                                                                                                                                                                                2. Documentation Methods
                                                                                                                                                                                                                                                                                                                                                  1. Work Instructions
                                                                                                                                                                                                                                                                                                                                                    1. Visual Standards
                                                                                                                                                                                                                                                                                                                                                      1. Process Charts
                                                                                                                                                                                                                                                                                                                                                        1. Training Materials
                                                                                                                                                                                                                                                                                                                                                        2. Maintenance and Improvement
                                                                                                                                                                                                                                                                                                                                                          1. Regular Review
                                                                                                                                                                                                                                                                                                                                                            1. Update Procedures
                                                                                                                                                                                                                                                                                                                                                              1. Employee Feedback
                                                                                                                                                                                                                                                                                                                                                                1. Continuous Enhancement
                                                                                                                                                                                                                                                                                                                                                              2. Root Cause Analysis
                                                                                                                                                                                                                                                                                                                                                                1. Problem-Solving Approach
                                                                                                                                                                                                                                                                                                                                                                  1. Systematic Investigation
                                                                                                                                                                                                                                                                                                                                                                    1. Data-Driven Analysis
                                                                                                                                                                                                                                                                                                                                                                      1. Team-Based Solutions
                                                                                                                                                                                                                                                                                                                                                                        1. Prevention Focus
                                                                                                                                                                                                                                                                                                                                                                        2. Five Whys Technique
                                                                                                                                                                                                                                                                                                                                                                          1. Question Formulation
                                                                                                                                                                                                                                                                                                                                                                            1. Cause Tracing
                                                                                                                                                                                                                                                                                                                                                                              1. Root Cause Identification
                                                                                                                                                                                                                                                                                                                                                                                1. Solution Development
                                                                                                                                                                                                                                                                                                                                                                                2. Fishbone Diagram
                                                                                                                                                                                                                                                                                                                                                                                  1. Cause Categories
                                                                                                                                                                                                                                                                                                                                                                                    1. Brainstorming Process
                                                                                                                                                                                                                                                                                                                                                                                      1. Relationship Mapping
                                                                                                                                                                                                                                                                                                                                                                                        1. Priority Setting
                                                                                                                                                                                                                                                                                                                                                                                        2. Other Analysis Tools
                                                                                                                                                                                                                                                                                                                                                                                          1. Pareto Analysis
                                                                                                                                                                                                                                                                                                                                                                                            1. Scatter Diagrams
                                                                                                                                                                                                                                                                                                                                                                                              1. Control Charts
                                                                                                                                                                                                                                                                                                                                                                                                1. Histogram Analysis

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                                                                                                                                                                                                                                                                                                                                                                                            3. Understanding Waste (Muda, Mura, Muri)

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                                                                                                                                                                                                                                                                                                                                                                                            5. Lean Leadership and Culture