MODULE 1:

THE LEAN CHALLENGE PRESENTS

Your Personal Lean Roadmap

A teaching guide for the Lean Coach

Lesson 1:  Welcome to The Lean Challenge

  • The first meeting with coach and students

  • Get to know one another

  • Explain the role of the coach

  • Share points of interest:

    • Name

    • Hobbies or sports or pets; family

    • Experience with Lean

    • What do the students want from the Lean training?

Lesson 2: Table of Contents

  • Briefly review the table of contents  

Lesson 3:  Your Student Dashboard

LEAN COACHING COURSE GUIDEINES

MODULE 2:  BACKGROUND OF LEAN 

Lesson 4:  NUMMI Story 

  • Briefly discuss your experience with NUMMI

  • Main point is that a large auto plant where everyone was told Lean will never work there, ignored the comments and went on to make the best car in the world by using Lean methods and concepts.

Lesson 5:  Why Lean? 

  • Review main points of the lesson with the class

  • Need to compete but your competition has all of the same equipment, ingrediencies you have

  • But Lean offers a new way of doing business.

MODULE 3:  FIVE PRINCIPLES OF LEAN

Lesson 6:  Principle 1 - Create Value for the Customer 

Lesson 7: - Principle 2 - Map the Value Stream 

Attend the weekly conference call

Lesson 8: - Principle 3 - Make the Wok Flow 

Lesson 9: - Principle 4 - Create a Pull System

Lesson 10: - Principle 5 - Continuous Improvement 

Note to coaches: These next few lessons and modules can be completed at the pace you and the student agree to.

5S can be challenging as it depends on the size of the area to be 5S and also on the difficulty of the 5S.

The goal is to complete this course in a 4 month period. You may need to discuss this with the student’s leader about how thorough you want the students to be especially if there is only 1 student or in another case there could be an entire team of students.

Module 4 - THREE TYPES OF WORK   

lesson 11 - Three Types of Work 

Module 5 - 8 TYPES OF WASTE  

Lesson 12: - Waste #1 - Defects or Correction 

Lesson 13: - Waste  #2 - Over Production 

Attend Weekly Coaching Session 

Lesson 14: - Waste  #3 - Waiting 

Lesson 15: - Waste  #4 - Neglected Talent 

Lesson 16: - Waste  #5 - Transportation 

Lesson 17: - Waste #6 - Inventory 

Lesson 18:  Waste #7 - Motion 

Attend Weekly Coaching Session 

Lesson 19: - Waste #8 - Overprocessing 

MODULE 6:  GETTING READY FOR "5S"

Lesson 20: - How Lean Can Help You and Your Business 

Lesson 21: - Welcome to 5S Workplace Improvement 

Lesson 22: - What is "5S"?

Lesson 23:  - Preparation for "5S"

Lesson 24: - Red Tagging 

MODULE 7:  THE GEMBA 

Lesson 25:  Define the GEMBA 

Lesson 26: - Preparing to Visit the GEMBA 

MODULE 8: "5S"

Lesson 27: - Step 1 - SORT 

Lesson 28: - Step 2 - Set-in-Order 

Lesson 29: - Step 3 - Shine 

Lesson 30: - Step 4 - Standardize 

Lesson 31: - Step 5 - Sustain