Step by Step Kaizen Practitioner Mastercourse for Beginners

Explore lean concepts by identifying muda, muri, and mura, learning to standardize work, manage takt time, and apply just-in-time and Kanban to level production and reduce waste.

Apply the 5S method: sort, straighten, shine, standardize, sustain, to create a safer, more efficient, and disciplined workplace with lasting quality and reduced defects.

Explore simulated 5S case studies that show sorting, set in order, inspection, and standardization through color-coded bins and designated cleaning roles.

Prioritize multiple projects using a project prioritization matrix to evaluate duration, cost, ROI, complexity, and resources, then score, weight, and rank to determine the optimal sequence.

Explore Gemba Walk as a lean leadership practice—go and see, ask why, show respect—covering benefits, ground rules, and steps from purpose identification to root-cause based gap closure.

Select key performance indicators aligned with strategic goals, quantify waste, and empower plant floor employees, applying smart criteria and sector-specific indicators for manufacturing, service, and business operations.

Set smart goals to gain long term vision and motivation, using specific, measurable, attainable, relevant, and time-specific criteria. Ask who, what, where, when, which, and why to define tangible progress.

Play a game to practice smart goals, evaluating specificity, measurability, attainability, relevance, and timeliness toward becoming top marketing training provider in Okinawa with 10 Fortune 500 clients by year end.

President Kennedy set a specific, measurable, attainable, relevant, and timely goal to land a man on the moon and return him safely.

Engage in continuous improvement by embracing lean and quality management, value learning, and seek support through captions, speed controls, direct messaging, and reviews of the course.

Develop a 30-60-90 action plan tracking actions, who, and when; share with management for alignment, with month one orientation, month two targets, and month three fine-tuning and controls.

Define goals and objectives and establish a data collection methodology with repeatability, reliability, reproducibility, accuracy, and stability across pre, mid, and post phases. Involve the team for on-site collection.

Explore sampling concepts, determine sample size, and compare probability and non-probability methods, including simple random, systematic, stratified, and cluster sampling, for unbiased population representation in lean six sigma contexts.

Analyze defects with a concentration diagram, a graphical checksheet that marks defect locations and frequencies to collect data, identify origins, and guide improvement.

Explore histograms, a bar-graph variant for continuous data showing frequency distributions with no gaps and bar area proportional to frequency. Discover how shapes reveal process variation and capability for improvement.

Learn to draw histograms in Excel using two methods, including a template; enter data in green spaces, leave pink boxes unchanged, and view frequencies and percentage.

Learn to generate a histogram in Minitab from defects per 10,000 items, and customize binning, bar counts, and axis labels to analyze data shape and spread.

Explore how scatter diagrams reveal relationships between two variables, identify positive and negative correlations, and assess correlation strength with a line of best fit.

learn to create scatterplots in excel using the insert tab, choose from simple or smooth-line scatter plots, input x and y data, and use r-squared to assess the relationship.

Explore the relationship between sales and advertisement using a scatter plot in Minitab. Learn to create simple scatter plots and advanced variants with regression, groups, and connect lines.

Explore how control charts track process changes over time by plotting data in time order with a center line and upper and lower control limits to assess stability.

Learn to construct an individual control chart (I chart) in Minitab for continuous data not collected in subgroups, comparing pre-phase and post-phase times and confirming data stay within control limits.

Explore cause and effect analysis using the fishbone diagram (Ishikawa) to identify multiple root causes and organize ideas with 4S fishbone, 8P fishbone, and 6M/8M categories, including branching sub-causes.

Draw a fishbone diagram to define the problem, brainstorm major factors, and use why-why analysis to reveal sub-causes and causal relationships.

Use the Excel fishbone diagram template to map causes and subcauses, choose among 8P, 8M, 6M, and 4S templates, and edit the effect or problem statement.

Master fishbone diagrams in Minitab 2018 and 2019, including 4S fishbone for root cause analysis and brainstorming in service industries, with a downloadable free template.

Learn to build a 4S fishbone diagram in Minitab, identifying supplier, surrounding, system, and skills causes, using the quality tools, and customize labels and subcauses.

Apply the 6M fishbone framework with Minitab to identify root causes across measurement, material, personnel, machine, method, and environment in a manufacturing case study.

Explore the 8p fishbone framework to diagnose marketing and business issues across people, place, procedure, promotion, process, product, and policy.

Pareto analysis identifies the 20 percent of causes that drive 80 percent of problems, boosting productivity, profitability, and customer experience.

Learn to perform pareto analyses using an Excel template that auto-sorts causes by frequency, demonstrates the 80 percent rule, and highlights key drivers for beginners.

Draw a pareto chart from process inputs in Minitab 2019, showing five factors: retail operators, computerized system, checking zones, card usage, and system quality driving 80 percent of the score.

Develop effective brainstorming by combining structured and unstructured methods under a facilitator and recorder, and follow seven steps from defining objectives to categorizing, prioritizing, action planning, and follow-up.

Benchmarking drives quality by comparison to stay competitive and become a world-class leader. It outlines ten steps, from selecting subjects and partners to gathering KPI data and sustaining improvements.

Explore how the five why analysis, a core tool in A3 analysis and Six Sigma DMAIC, uncovers root causes across personal, organizational, and business problems.

Apply the five whys analysis to trace the Jefferson Memorial cement failure to a lighting schedule that attracts insects, which feed pigeons, leading to frequent cleaning and eventual cement failure.

Learn about poka yoke, or mistake proofing, and how prevention, facilitation, and detection strategies reduce errors in daily systems. Explore real-world examples and design approaches.

apply the pdca cycle—plan, do, check, act—to drive continuous improvement, test ideas, analyze results, and institutionalize successful changes for collaborative problem solving.

Master work standardization as the kaizen baseline, backed by sops and standardized work documents. Align takt time, cycle time, and work sequence with in-process stock and three key worksheets.

Master the production capacity sheet template to compute maximum capacity for machines and processes, record operation times, tool changes, setup, and the minimum capacity formula; compare with takt time.

Explore the standardized work chart, which maps work sequence movements and layouts, helps verify adherence and spot problems, and provides an easy-to-use Toyota-style template for weighing, mixing, filling, and packaging.

Examine the standard work combination sheet, takt time, and times for manual, motion, and auto to reveal kaizen opportunities to improve quality checks, assembly, tests, and packaging.