Innovative Lean Deployment Workshop
(A Three Days Workshop)

The workshop will cover core concepts related to

1. Principles of Lean and
2. Identification of Waste (with application in workplace through the Ohno circle)
3. Standardization of Work, introduction of Continuous Flow, Work allocation and managing productivity of teams
4. Concepts related to strengthening of the skills related to

  1. Systems thinking: Participants will learn to identify the root-conflicts that need to be tackled to resolve the bigger problem. The tool covered will be Root Conflict Analysis (RCA+)
  2. Envisioning the Ideal result: Participants will learn to set the strategic direction for the channelizing their thoughts related to generation and evaluation of ideas.
  3. Identifying Resources:
    1. Ability to identify resources at different levels of granularity (hidden resource, readily available resource, derived resource)
    2. The tools covered include ENV (Element-Name of Parameter-Value of Parameter)
  4. Resolving Contradiction
    1. Identifying contradiction
    2. Resolving contradiction by applying principles of resolving contradiction

Day-1: Morning session

  • Introduction to Lean
  • Understanding the Lean Concepts
    • Eight Types of Wastes
    • Group Exercise on Eight Types of Waste

Day-1: Afternoon session

  • System of Powerful Thinking
    • RCA+(Root Conflict Analysis)
      • Modeling the current situation to unravel the root conflicts leading to Waste
      • Group Exercise on RCA+

Day-2: Morning session

Tongs Model
Hill Model
Identifying and Resolving Contradictions
Formulating Contradictions as Element-Name of Parameter-Value of Parameter (ENV) Model
Rules for Selecting Contradiction for resolution

  • Tongs Model
  • Hill Model
  • Identifying and Resolving Contradictions
    • Formulating Contradictions as Element-Name of Parameter-Value of Parameter (ENV) Model
    • Rules for Selecting Contradiction for resolution
      • Identify the Main Production Process (MPP)
      • Choose the Contradiction that will help achieve the Main Production Process (MPP) and meet the Most Desired Result (MDR)
      • Apply principles of resolving Contradiction
      • Compare solution directions with Ideal Final Result (IFR)
    • Group Exercise on Resolving Contradictions

Day-2: Afternoon session

  • Introduction to Value Stream Mapping (VSM)
    • Creating the Value Stream Map
      • Current State Map
    • Introducing Continuous Flow in Future State Map
    • Group Exercise on Value Stream Mapping

Day-3: Morning and Afternoon session

  • Standardized Work
    • What are the work elements?
    • Paper Kaizen
    • Pre-requisites for standardizing work
      • Standard Work guidelines
      • Standardized work chart
      • Standardized Work combination Table
    • Importance of Visual Controls
  • Communicating Lean
  • Assessing the Lean Progress
  • Group Exercise on Standardization of Work