Flow and Process Kaizen Objectives: ● familiarize servant leaders with just-in-time production principles & methodologies ● assist lean leaders in “seeing the flow” within their chosen focus “Model” or “Pilot” value stream flow and its sub-component operational processes ● assist lean leaders in creating a comprehensive current state value stream flow map of their “model” value stream and conducting a process kaizen of an important constraining sub-component process ● assist servant leaders in understanding how just-in-time principles and practices can significantly improve flow within the value stream and its component processes ● assist lean leaders in visualizing, then developing an aggressive, yet feasible future state value stream flow and sub-component process improvement designs ● coach leaders in designing an improvement sustaining lean transformation plan ● assist servant leaders in developing an effective lean leadership framework and sustaining performance metrics for their value stream and operational processes. To achieve these objectives, participants will: ● practice, through discussions and case study illustrations, basic value stream flow mapping and process kaizen methods, team building, and servant leadership roles and responsibilities. ● develop both current and future state flow maps of their focus “model” value stream. ● hands-on kaizen a constraining process component of the “model” value stream ● learn lean leadership roles and responsibilities and appropriate lean performance metrics to sustain kaizen improvements. Day1: Current State Value Stream Mapping ● introductions/workshop structure ● lean fundamentals ● flow and process kaizen ● a framework for transformation ● flow kaizen value stream mapping process ● dock-to-dock value stream mapping ● cross-functional process mapping ● team current state flow mapping ● team current state presentations ● group current state flow map consolidation ● group current state opportunities 。 Day2: Improving flow and processes ● group final current state flow map design ● regulating demand and production flow ● enhancing production flow ● balancing workload ● work cell layout and flow ● cellular manufacturing ● visual process control ● just-in-time flow demonstration ● pull processes ● work-in-process flow ● materials flow 。 Day3: Inventing a better future state flow ● future state flow mapping process ● case study future state examples ● team future state flow development ● team future state flow Mapping ● team future state presentations ● group future state flow map consolidation ● group future state flow opportunities discussions ● group future state impediments ● component impediment process kaizen methodology ● documenting process reality. Day4: Future State Mapping. ● identifying component process wastes ● team impediment waste countermeasure design ● team process kaizen improvement presentations ● group process kaizen improvements consolidation ● group improvements validation (pausing “to smell the roses”) ● group planning for on-floor work ● group process kaizen shop floor improvements execution. Day5: Becoming lean ● group process kaizen shop floor improvements execution ● team documentation of improved processes ● team measurement of process kaizen results ● team process kaizen results presentation ● becoming lean - kaizen implementation and follow-up ● organization transformation planning ● wrap-up and workshop's value.