This document outlines a training program on Lean Manufacturing practices. It lists several Lean tools and concepts that will be covered in the training, including introduction to Lean, identifying root causes, 5S, risk assessment with FMEA, takt time, affinity diagrams, QRQC steps 1 and 2, PDCA, FTA, building control plans, 5 whys, SMED, poka-yoke and auto-quality. The training will total approximately 97 hours and cover topics such as process improvement philosophies, identifying issues, organizing workspaces, risk analysis, workflow analysis, problem solving tools, sustaining improvements and mistake proofing.

1. Janv 2013
BEN-GAMRA A.
Automotive Quality Manager
VAQ Auditor (following VAQ A2102 Rev4 – 2007 January )
( Delivred by VAQ JL Aucan / L. Virin 2008 )
Lean Manufacturing Practicien
Based on Automotive company experience

2. Janv 2013
- Theme & Sections :
• Introduction to Lean 3 Hours
Lesson Description: An introduction to Lean including a brief history, the philosophy of Lean, and a summary of some common
Lean tools and concepts.
• Identify Root Causes – C&E Diagram 4 Hours
Lesson Description: An extension of the topic on identifying root causes using a cause & effect (C&E) diagram that will lead toward
building a data collection plan (DCP).
• 5S Program 3 Hours
Lesson Description: An introduction to the Lean concept of the 5S program and how it can help keep improve and sustain
efficiency in a process.
• Risk Assessment with a FMEA Tool 8 Hours
Lesson Description: A review of the importance of assessing risk and how to measure it using a FMEA tool.
• Takt Time 4 Hours
Lesson Description: An introduction to the takt time metric and how they can be used to measure process flow.
• Brainstorm Solutions with an Affinity Diagram 2 Hours
Lesson Description: A review of how we can build an Affinity Diagram as part of a workout for brainstorming solutions that will fix
a root cause.
• QRQC Step 1 8 Hours
Lesson Description: A tool which can be powerful for quality control and process default follow up based on reactivity and logical
thinking mindset .
Based on Automotive company experience

3. Janv 2013
- Theme & Sections :
• QRQC Step 2, 3 8 Hours
Lesson Description: Define global management of QRQC and implementation on GENBA based on logical thinking mindset .
• PDCA ( Deming Wheel ) 8 Hours
Lesson Description: The main tool of problem resolving and Deming wheel review .
• FTA ( Factor Tree Analysis ) 8 Hours
Lesson Description: An introduction to the extended topic on identifying root causes using a variety of tools that will help build a
data collection plan (DCP).
• Building a Control Plan 6 Hours
Lesson Description: A review of how to build a control plan to help sustain the implemented improvements.
• Control Phase Roadmap 3 Hours
Lesson Description: A detailed roadmap through the Control phase of the DMAIC methodology that navigates the user
• 5Whys ( Complement to FTA ) 4 Hours
Lesson Description: Help identify the root cause of a problem, determine the relationship between different root causes of a
problem.
• SMED (Single Minute Exchange of Die s) 6 Hours
Lesson Description:I s a tool used in the improve phase of a DMAIC project to improve existing set-up times enhancing the flow of
products and alleviating a constraint.
• Poka-yoke & Matrix Auto-Quality 8 Hours
Lesson Description: Poka yoke, also called mistake proofing, is a simple method to prevent defects from occurring in your business
processes.
Based on Automotive company experience