TRAINING TO

„LEAN BASICS” MODULE

PART I

1. Run „Waste Walk” in the area of your choice and identify

as much loss as possible.
2. Find 3 ways that will eliminate or reduce the identified
loss
3. Ask 10 GEMBA questions to 5 operators (in the area of
your choice) then review the responses. Are the
responses „normal”?
PART II
1. Run analysis of usefulness of all tools and objects in the area of your choice. Remove unused items
from the workplace. Then, for the items left, find a place and mark it. Take pictures before and after.
2. Measure processing times performed by operators divided into activities on a production line of your
choice. What are the differences in work load? Which operator is the most overloaded and which one
the least? You can use „Time analysis DEMO” tool available in materials for download.
3. Count Work in Progress (WiP) between the workstations of a selected production line. Answer the
question – is there a one piece flow? If not - what actions should be taken to reduce the amount by
half?
4. Identify the root cause of a loss on the production line using the „5 x Why” analysis.
5. Using the Kanban Board schedule tasks for a Sprint (weeks 1-4) and write them down on post-it notes
in the ‘to do” column. When a task changes status, move a post-it note to the relevant column then
summarize how many tasks you managed to complete any why.