Berka Solutions Lean OpEx Training Program
Team Upskilling to drive Transformation
Lean Operational Excellence Training Program Overview
Our Lean Operational Excellence training program is strongly based on Lean and Continuous Improvement methodologies with blended coaching and mentoring in a collaborative style.
This program is structured in four modules allowing the client team to understand and integrate lean into their culture over a period of time. Each module builds on the previous module and are similar to the industry standards of White Belt, Yellow Belt and Green Belt, and supported with specific Change Management, Leadership and Strategy workshops for the leadership team.
Training Program Details
By completing our comprehensive Operational Excellence Training Program, participants will gain a thorough understanding of Lean and Continuous Improvement methodologies, equipped to drive transformative changes within their organisations. The learning outcomes encompass the following:
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Fundamental Lean Principles: Understand and apply the core principles of Lean, including waste identification and reduction, to streamline processes and enhance efficiency.
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Effective Communication and Engagement: Master the art of standardised communication and engagement within the organisation, fostering a culture of continuous improvement and collaboration through the implementation of the 6-S program.
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Root Cause Analysis and Problem-Solving: Develop advanced problem-solving skills, utilising root cause analysis techniques such as the 5 Whys and Ishikawa diagrams, and implement effective solutions through methodologies like PDCA and DMAIC.
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Project Implementation and Management: Execute and manage Lean projects from start to finish, applying project management tools and techniques to ensure successful implementation and sustained continuous improvement.
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Leadership and Change Management: Gain insights into change management theories and leadership strategies, empowering participants to lead and drive organisational transformation through Lean practices and strategic planning.
Have a busy work schedule?
Our program's 80% online and 20% in-person format lets you complete your training anytime, anywhere, and at your own pace.
Delivery Methods
The training modules are delivered through the blended learning with On-Line & Face-to-Face coaching and mentoring approach in a collaborative style.
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Module 1, 2, and 3: Delivered online, these modules cover the foundational principles of Lean, process improvement techniques, and strategic implementation methods. You will have access to interactive materials, video lectures, and practical exercises to reinforce your learning.
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Module 4: This module conducted in person, focuses on hands-on applications and real-world problem-solving. You will work closely with our expert trainers to apply what you have learned in a practical setting.
Lean OpEx Training Module 1 -Basic Introduction to Lean & Continuous Improvement
Module Contents
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Definition of Lean Principles
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Definition of Waste - TIMWOODS
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Identifying waste in the current organisational process
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Kaizen – Continuous Improvement Cycle
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Biases and mindset challenge
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Team Challenge
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Process Flow Mapping
Lean OpEx Training Module 2 -Operational Excellence – RCA, Problem Solving & A3s Objectives
Training Program Objective
The objective of the Operational Excellence program is to train the participants in the principles of root cause analysis including the 5 whys, the Ishikawa diagram and 5W1H analysis. Following the development of root cause analysis, the participants will focus on developing their problem-solving techniques. The program will focus on the role of Gemba in problem solving, understanding cognitive bias, and solution mapping through PDCA and DMAIC models, specifically in setting out A3s.
Module Content
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Root Cause Analysis (RCA)
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5 Whys
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Ishikawa Diagrams
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5W1H Analysis
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Problem Solving
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Gemba
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Cognitive Bias
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PDCA
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DMAIC
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A3
Lean OpEx Training Module 3 -The Visual Factory – Communications, Engagement & the 6-S Program
Training Program Objective
The objective of the communication, engagement and 6-S program training is to develop a clear understanding of the importance of communication and engagement within the organisation. The program focuses on Tier communication, shared language and behavioural standards of respect, engagement, collaboration, and feedback. The 6-S program focuses on a visual implementation of the Operational Excellence Program to demonstrate the benefit of implementing the Operational Excellence Program, and the benefits that the program will yield to both the employee and the organisation.
Module Contents
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Tiered, standardised communication.
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Compliance, People, Customer, Operations, and Innovation.
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Growth mindset awareness
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Organisational Behavior. workshop and awareness training
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6-S Program Training and implementation
Lean OpEx Training Module 4 -Operational Excellence – Green Belt Project Implementation
Training Program Objective
The objective of the Operational Excellence program is to train, coach and mentor the participants in identifying and implementing a Green Belt project including the application of waste identification, process mapping, root cause analysis to establish the current state, and problem-solving techniques to determine the future state and the associated action plan required to deliver continuous improvement. The Operational Excellence program will be mapped through project management techniques and presented as an A3 to track performance and demonstrate the continuous improvement process in action.
The module will be delivered through individual coaching sessions and team workshops to ensure effective project scoping, and implementation.
Module Contents
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Lean Principles
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Waste Identification
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Root Cause Analysis
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DMAIC
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Problem Solving
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Action Planning
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Project management
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A3
