Lean Zero-Defects

2 days

Lean Thinking for absolute product and process quality
course code 3.4

What is the course for

#1

Obtain a general overview of the evolution of the concept of quality

#2

Apply Lean concepts to reducing qualitative waste in all processes

#3

Learn how to use the most appropriate tools to implement a Lean zero-defects program

Today, when we speak about “Quality”, we speak of a word that has become inherent to any business and is increasingly emblazoned with certifications and grandiose slogans. Yet even today, companies that truly succeed in transforming themselves into lean systems of people and processes geared towards an absolute reduction of flaws and to eliminating the qualitative nonconformities at the root of the errors are rare. Paradoxically, there are still cases where quality is likely to become an overbearing bureaucratic burden, devoid of its real goal, which should be ensuring maximum customer satisfaction. Unfortunately, in a number of companies it is still difficult to get the concept across that the highest quality at the source in any operation is the true way to reduce the costs of many production activities.

When customers are truly at the centre of a business, an increasing number of employees naturally gain more and more decision-making power in addressing quality issues, reducing the need for more structured supervision. The Lenovys Lean Zero-Defects training course promotes this profound cultural change, oriented to pragmatically acquiring management and operational practices that ensure the implementation of a system of people and processes to obtain the highest qualitative excellence at minimal cost to the business. This is achieved by progressively shifting toward preventing flaws rather than merely reacting to them, through the proactive contribution of each resource involved in the production value chain.

Goals

  • Obtain a general overview of the evolution of the concept of quality
  • Apply Lean concepts to reducing qualitative waste in all processes
  • Understand how to promote a customer-oriented culture, both internally and externally
  • Learn how to use the most appropriate tools to implement a Lean zero-defects program

Addressed to

  • Executives and Operations Area Directors
  • Middle Management in the Operations Area
  • Team and Group Leaders
  • Continuous Improvement Agents
  • Line operators

Contents

Quality in the company

  • The historical evolution of quality: from final inspection to the zero-defects mentality
  • Customer satisfaction as a strategic business value
  • The end customer and the internal customer: social and communicative issues and problems of values
  • Recognise and identify the implications of  “non-quality” at all levels of the company
  • The reworking trap

The Lean zero-defects method

  • Jidoka as the pillar of the Toyota Production System
  • Quick response management as a Lean zero-defects framework
  • Line meetings and stand-up meetings
  • The deployment of defectiveness and the aggressive lost quality strategy
  • Problem solving and the PDCA cycle
  • Claim management and 8D
  • Social and motivational aspects in a successful Lean zero-defects programme

The Lean zero-defects operating tools

  • Andon and the importance of confronting problems at their root
  • The Control Plan
  • The self-management matrix as a continuous improvement tool
  • From product control to process control: capability and SPC
  • The push towards foolproof solutions (Poka Yoke)
  • Prevention tools: DFX, FMEA, reliability tools
  • The links between the various corporate bodies  contributing to zero defects: how to reinforce and synergise them

You will experience

  • How to recognise and quantify the costs associated with lack of quality
  • How to implement a strategy to eliminate qualitative waste
  • How to promote a culture oriented towards customer satisfaction
  • How to gradually shift attention from correcting defects to preventing them.

Download the in-company training catalogue