Lean Management in a Post-Pandemic World

Covid-19 has changed the whole business landscape worldwide. Organizations and businesses had never anticipated the Movement Control Order (MCO) to ever be enforced especially within a pandemic context. Such enforcement had caused a sudden halt in daily business operations, causing huge financial loss to a large number of businesses. However, even as we are seeing signs of this pandemic subsiding, the local and global markets have changed significantly. Our current volatile, uncertain, complex, and ambiguous world, or better known as the VUCA world calls for more efficient business practices. Hence, lean management, which focuses on value maximization and process enhancement, such as waste minimization, value stream optimization, and quality management, is needed now more than ever.

Course Outline

Module 1: Introduction to Lean Management

• Definition
• How it started?
  • Toyota Production System (TPS)
• Comparison: Lean, Six Sigma, and Lean Six Sigma

Module 2: Mastering the Quality Function Deployment (QFD) Tool

• Definition
• The core of QFD – House of Quality
  • Voice of customer
  • Weight
  • Controlled factors
  • Relationships
  • Importance factors
  • Competition
  • Roof Relationships
• Hands-on application

Module 3: Lean Principles I: Pull Production as an Alternative to Push Production

• Push production
  • Batch production
• Pull production
  • Single piece flow
  • Just-in-time (JIT)
  • Jidoka
  • Heijunka
• Takt time
• Cycle time and Bottlenecks
  • Bottleneck optimization

Module 4: Lean Principles II: Managing Waste in Businesses

• The seven forms of waste – Waste of:
  • Defects
  • Overprocessing
  • Transport
  • Motion
  • Waiting
  • Inventory
  • Overproduction
• The eighth form of waste – Waste of:
  • Talent
  • Information
  • Skills

Module 5: Lean Principles III: Little’s Law and Seven Quality Control Tools

• Little’s Law
  • Definition
  • Formula and its application
• Seven Quality Control Tools
  • Ishikawa and histogram
  • Pareto chart
  • Flow charts, scatter plots, run/control charts, check sheets
• Hands-on application

Module 6: Lean Principles IV: Value Stream Mapping

• Definition
• How to apply value stream mapping
• Construct a value stream map
  • Hands-on application