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Lean as a Strategy to Operational Excellence

Lean/Operational Excellence

In this course, we go back to basics and explain the essence of Lean/TPS as a strategy, what it’s not, and the framework of its (universal) principles.

We will explain the framework in detail to help you, as a leader, better understand the full implications of explicitly choosing Lean as a strategy for Operational Excellence and its impact on the organization, operationally and culturally. The ‘why’ behind the associated Lean tools will be covered, but the ‘mechanics’ of the tools will not. These will be covered in other courses we will offer later this year (for manufacturing and office/service/healthcare organizations). Implementing tools is not an end in itself. Because the tools are highly contextual, a cut-copy-paste approach is typically unsuccessful.

We will also devote time to the typical challenges and pitfalls that prevent Lean from delivering the expected breakthrough results in practice in many organizations. We will cover the implications of choosing Lean as a strategy for Operational Excellence for leadership, from how to make the right choices to leadership behaviors and creating the right circumstances for building a continuous improvement culture.

Finally, participants will be asked to reflect on their own organization’s current and future challenges, how Lean/Operational Excellence can address these challenges, and what steps can be taken to take the organization to the next level of maturity in this area. A certificate will be awarded following the presentation of their findings and conclusions.

The course instructor is dr. ir. Dirk Van Goubergen, associate professor at the Department of Operations Analytics and president of the VanGoubergen P&M Lean Academy. He has 30 years of international experience with Lean/TPS in Europe, Asia and the Americas in large and small organizations in all sectors (including Toyota itself). He will discuss many real-life examples from his experience in different types of organizations.

The course lasts three days. Discover more below

The Curriculum

  • Day 1 & 2

    Introduction to Lean

    • Where it comes from (to better understand what it is and what Lean is trying to do)
    • What Lean is and what it’s NOT (Lean as a business strategy)
    • The essence of Lean Thinking (the 5 steps of Womack and Jones) - Lean is NOT just about eliminating waste

    Lean in 4 key themes

    Key theme 1: Value vs. Waste (Resource perspective)

    • What is value? How do you teach employees about value?
    • Waste as a temporary countermeasure
    • Challenges: seeing the waste, failure demand, etc.

    Key theme 2: Flow in Value Streams (Product perspective)

      • Flow vs. Resource Efficiency
      • The importance of value stream design
      • Challenges: suboptimization, shared resources, push driven value streams, etc.

    Key theme 3: Visual Management

      • Making abnormal situation visible (workplace, method, flow, quality, etc.)
      • The importance of standards/standard work
      • Standard work to react to problems (plan B)

    Key theme 4: Striving for Perfection 

      • Kaizen culture and the Learning Organisation
      • Vocabulary/communication
      • Dealing with Problems, TBP (Toyota Business Practice), PDCA
      • Importance of Leadership commitment/participation and the ownership of continuous improvement
      • HRD (Human Resources Development) strategy

    Lean vs other approaches (Six Sigma, QRM, Agile/SCRUM,..)

  • Day 3: Personal reflection

    Assignment – (online) presentation of report

    • Is Lean as a strategy an approach that meets the (strategic) needs and challenges within the organization?
    • What is the organization’s current level of Lean/Operational Excellence implementation?
    • Force Field Analysis - What supporting and opposing conditions currently exist that require executive/leadership attention?
    • What are the next steps?

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