RIBCON
Kaizen, meaning ‘continuous improvement’ in Japanese, is a philosophy and a practical methodology for achieving sustainable efficiency, quality, and productivity improvements. Through small, incremental changes driven by employees at all levels, organizations create long-lasting cultural transformation.
The focus of Lean Kaizen is to continuously reduce Business Throughput time by identifying, reducing and eliminating MUDA (Waste) .The core idea is to maximize customer value while minimizing waste. We help organisations integrate Kaizen into their culture with extensive Kaizen training programs.
Our Lean Kaizen training programs equip teams to implement various Lean Kaizen tools effectively in an organisation to drive operational excellence and continuous improvement. Lean your employees into Kaizen with practical learning programs, using a combination of educational presentations and case studies with experiential simulations and games, group work, and ‘hands-on’ practice at the Gemba.
Our team has conducted over 5000 Kaizen workshops across 80+ different industries & Trainings on, 5S, Lean Manufacturing, Just-In-Time, Total Productive Maintenance (TPM), Total Quality Management, Total Flow Management (TFM), Daily Work Management, Preventive Maintenance, Internal Kaizen Expertise and Hoshin Kanri.
Kaizen Certification Level 1 Training is a 2-day course designed to provide participants with skills and knowledge to identify and analyse problems, implement and review kaizen projects successfully through internal Kaizen workshops
Preparing individuals for the Kaizen journey by addressing resistance to change, understanding the need for change and learning how to shift paradigms for better results through team games and case studies.
Introducing core principles of Kaizen, understanding value adding, non-value adding activities, learning 7 wastes and practice waste identification through shop floor exercises.
Learn to map the current state of processes, work in groups to analyze inefficiencies, and design a future state value stream map for waste elimination and improved flow.
Understanding principles & tools of Flow Management including Time & Motion study, Line balancing, Cycle time, Takt Time, Layout design as per flow principles and Standard work.
Creating a Pull System introducing the use of Kanban and effective inventory management techniques to optimise inventories and eliminate stock outs
Learn to identify and address the underlying causes of problems with tools like Pareto, Cause & Effect, and 5-Why Analysis Pareto, Cause & Effect and Why – Why Analysis.
Kaizen Level 2 Certification Training is a 3-day course aimed to provide participants with skills and knowledge on Key TPM (Total productive maintenance) pillars i.e. implement key steps of Autonomous Maintenance, Planned Maintenance and Kobetsu Kaizen (Focused Improvement) and implement projects to reduce OEE Losses.
Preparing individuals for the Kaizen journey by addressing resistance to change, understanding the need for change and learning how to shift paradigms for better results through team games and case studies.
Introducing core principles of Kaizen, understanding value adding, non-value adding activities, learning 7 wastes and practice waste identification through shop floor exercises.
Learn to map the current state of processes, work in groups to analyze inefficiencies, and design a future state value stream map for waste elimination and improved flow.
Understanding principles & tools of Flow Management including Time & Motion study, Line balancing, Cycle time, Takt Time, Layout design as per flow principles and Standard work.
Creating a Pull System introducing the use of Kanban and effective inventory management techniques
Learn to identify and address the underlying causes of problems with tools like Pareto, Cause & Effect, and 5-Why Analysis Pareto, Cause & Effect and Why – Why Analysis.
Practical understanding of Total Productive Maintenance (TPM) – one of the most effective and successful technique to enhance equipment effectiveness and reduce costs
Overview of TPM Pillars and covering 3 main pillars
Kaizen Certification Level 3 Training is a 5-day course aimed to provide participants with advanced techniques for reduction of Major Equipment Losses, implement autonomous maintenance to eliminate abnormalities, establish standards and process improvement techniques for support functions.
Preparing individuals for the Kaizen journey by addressing resistance to change, understanding the need for change and learning how to shift paradigms for better results through team games and case studies.
Learn core principles of Kaizen, understanding value adding, non-value adding activities, learning 7 wastes and practice waste identification through shop floor exercises.
Learn to map the current state of processes, work in groups to analyze inefficiencies, and design a future state value stream map for waste elimination and improved flow.
Understand principles & tools of Flow Management including Time & Motion study, Line balancing, Cycle time, Takt Time, Layout design as per flow principles and Standard work.
Create a Pull System introducing the use of Kanban and effective inventory management techniques
Learn to identify and address the underlying causes of problems with tools like Pareto, Cause & Effect, and 5-Why Analysis Pareto, Cause & Effect and Why – Why Analysis.
Practical understanding of Total Productive Maintenance (TPM) – one of the most effective and successful technique to enhance equipment effectiveness and reduce costs
Overview of TPM Pillars and covering 3 main pillars
Autonomous Maintenance Step 2 & 3:
Developing countermeasures against repeat abnormalities, hard to access, hard to clean areas and establish standards for cleaning, lubrication, inspection and tightening
Planned Maintenance:
Spare Parts Management & Predictive Maintenance: design an effective spare-parts management system to ensure critical spares are available without excessive inventory and how to apply predictive maintenance tools (vibration, thermography, oil analysis, etc.) to prevent failures before they occur.
TWI:
Learn to measure and improve skills with shortest time using Job instruction methodology. design a Skill Matrix, and adopt structured on-the-job training techniques that accelerate learning, standardize skills, and ensure knowledge retention.
Quality Maintenance:
Implementation Steps & Poka Yoke (Mistake Proofing): preventing defects before they occur by maintaining equipment and process conditions at the ideal state. Understand Poka-Yoke (mistake-proofing) mechanisms to eliminate human and process errors.
Process Mapping to reduce Turnaround Time & Standardisation: Use process mapping techniques to map all process activities if a selected process, identify bottlenecks & non value adding activities, measure turnaround time, and create a future state map to achieve reduced process turnaround time through NVA / waste reduction
Kaizen trainings conducted
successful Kaizen projects
participants trained
Sharing of experience and case studies with practical application by Kaizen experts, worked across various industries and sectors.
The training program is tailored to align with organisation goals, by initial discussions with key stakeholders.
Practical learning through group activities, case studies, and simulation games, ensuring an engaging and hands-on experience at both classroom and shop floor of implementing Kaizen.
Train-the-Trainer program is led by a highly experienced trainer and Lean expert to enable internal capacity building and empower teams for ongoing success.
Flexible online and off-site Kaizen training programs designed to suit the needs of the organisation.
Participants will get certification only after the submission of defined Kaizen projects and results delivered, ensuring target outcomes are achieved for each project.
With experience across diverse industries and challenges, we deliver unparalleled insights and solutions especially designed as per the needs. For more details, contact us today!
