Lean Problem Solving and Reporting Process

Course Overview:

This training course equips participants with the knowledge and skills needed to effectively apply Lean problem-solving techniques and structured reporting processes. The course integrates Lean principles, root cause analysis, and structured reporting methodologies such as A3 reporting to drive continuous improvement and operational excellence.

Course Duration:

1-2 Days (Customizable based on depth and practice requirements)

Target Audience:

• Managers, Supervisors, and Team Leaders
• Lean Practitioners and Continuous Improvement Professionals
• Engineers and Quality Professionals
• Employees involved in problem-solving and process improvement initiatives

Course Objectives:

By the end of this training, participants will be able to:

1. Understand the core principles of Lean problem solving.
2. Identify and define problems effectively using structured methodologies.
3. Apply root cause analysis techniques (5 Whys, Fishbone Diagram, etc.).
4. Utilize Lean tools such as PDCA (Plan-Do-Check-Act) and A3 Thinking.
5. Develop effective countermeasures to prevent recurrence.
6. Create clear, concise, and impactful problem-solving reports.
7. Implement structured reporting processes to communicate issues and solutions.
8. Foster a continuous improvement mindset in their teams and organizations.

Learning Outcomes:

Upon successful completion of the course, participants will be able to:
✅ Identify and articulate problems using Lean thinking.
✅ Apply structured problem-solving techniques systematically.
✅ Use data-driven approaches to analyze and resolve issues.
✅ Develop and implement effective countermeasures.
✅ Document findings in A3 reports and other structured formats.
✅ Improve team collaboration in problem-solving efforts.
✅ Drive a culture of continuous improvement and waste reduction.

Course Outline:

Module 1: Introduction to Lean Problem Solving

• Overview of Lean Thinking and its impact on problem-solving
• Understanding waste (Muda) and inefficiencies
• Introduction to structured problem-solving

Module 2: Defining the Problem Effectively

• Importance of problem definition
• Problem statement techniques (SMART, 5W1H)
• Understanding customer impact and business relevance

Module 3: Root Cause Analysis Techniques

• 5 Whys Method
• Fishbone Diagram (Ishikawa)
• Failure Mode and Effects Analysis (FMEA)
• Data collection and validation

Module 4: Lean Problem-Solving Tools & Methodologies

• PDCA (Plan-Do-Check-Act) Cycle
• DMAIC (Define-Measure-Analyze-Improve-Control) overview
• Kaizen and Continuous Improvement mindset

Module 5: Developing and Implementing Countermeasures

• Brainstorming and selecting countermeasures
• Risk assessment and prioritization
• Implementation planning and change management

Module 6: Reporting and Communicating Solutions

• Introduction to A3 Thinking and Reporting
• Creating an effective A3 Report
• Visual storytelling and data representation

Module 7: Practical Application & Case Studies

• Hands-on case study exercises
• Group problem-solving activities
• Real-world examples and best practices

Module 8: Embedding a Problem-Solving Culture

• Leadership’s role in sustaining problem-solving culture
• Coaching and mentoring for continuous improvement
• Action planning for workplace application

Training Methodology:

The course employs a blended learning approach with a strong emphasis on hands-on practice and real-world applications, including:

🔹 Instructor-led presentations (Theory and concepts)
🔹 Interactive discussions (Real-life problem-solving scenarios)
🔹 Group activities & workshops (Team-based exercises)
🔹 Hands-on application (Use of actual company problems for practice)
🔹 Case studies & best practices (Industry examples)
🔹 Role-playing & simulations (Engaging learning experiences)
🔹 Assessments & feedback (Quizzes, reports, and instructor feedback)

Assessment & Certification:

✅ Knowledge Check Quizzes – Throughout the course
✅ Practical Application Assignment – Solving a case study using A3 methodology
✅ Final Project – Submission of an A3 report for evaluation
✅ Certificate of Completion – Upon successful participation and assessment