A starter kit for more effective and sustainable improvements

Duration: 2 Days

The Process Improvement Project Skills workshop presents the A3 Report as a systematic structure for process improvement. You will be able to identify the benefits of applying a structured and standardized process improvement framework to your organization’s change efforts through hands-on application in The Paper Factory simulation.

Cost: $14,000

Location: Lean Learning Center, Troy, Michigan.  Can be offered onsite at your location.

Starting Date(s):
Information to come.

Course Description

Waste is one of the most common process inhibitors, often creeping into processes, disguising itself as a process necessity and goes undetected. In this workshop, we explore seven specific types of waste, provide common examples of each, and provide strategies to challenge their existence within processes.

Then, you apply your newfound knowledge to The Paper Factory simulation, actively participating in a waste walk, directly observing the process, and identifying opportunities for waste elimination. From waste elimination we eliminate process variation with error proofing and visual management techniques.You return to your Paper Factory process to analyze and address any wastes or problems and implement improvements to dramatically change the results of your simulation process.

The ability to analyze the current state of a process to pinpoint problem areas and focus attention on actionable areas is pivotal to process improvement success. During current state discussions, the workshop provides specific strategies to analyze the current state of a process using a structured methodology of activities, connections and flows. You learn tools that can be used to document observations such as the top-down flow chart, activity-based map and product-process map.

Key Benefits

  • Analyze the current state of a simulated process and utilize observation tools to document findings.
  • Identify the seven types of waste that inhibit process performance.
  • Create an ideal state paragraph for a simulated process using the structure and criteria provided.
  • Document planned improvements using a structured and succinct report writing methodology.
  • Brainstorm error proofing strategies to prevent common everyday problems from occurring.
  • Utilize the current state analysis to eliminate waste and non-value added activities from a simulated process.
  • Develop an action plan that will enable learners to take immediate steps to implement process improvement back on the job.


Day 1: Analyzing the Current State: Identifying Target Conditions and Barriers

Analyze the current state of a simulated process with direct observation tools.  We will identify the seven types of waste that inhibit process performance.  You’ll create an ideal state paragraph for your simulated process and document your planned improvements using a structured and succinct methodology.

Day 2: Actions, Schedules, and Measures

Through Team Exercises, you use a real example to practice 5 Why problem solving on an A3 template.  Apply the principles of high agreement, PDCA, and After Action Reviews. Debrief and explore how what you learned applies to to your projects.


Lean Learning Center, Novi, Michigan