INFO TRAINING EFFICIENT LEAN MANAGEMENT 2026-2027

DESKRIPSI

Training Efficient Lean Management 2026–2027 merupakan program pelatihan yang dirancang untuk membantu organisasi meningkatkan efisiensi, produktivitas, kualitas, dan daya saing melalui penerapan prinsip-prinsip Lean Management secara sistematis dan berkelanjutan.

Lean Management merupakan pendekatan manajemen yang berfokus pada penciptaan value bagi pelanggan dengan mengurangi aktivitas yang tidak memberikan nilai tambah atau waste, memperlancar flow proses, meningkatkan kualitas, memperpendek lead time, mengoptimalkan penggunaan sumber daya, serta membangun budaya continuous improvement.

Dalam training ini peserta akan mempelajari konsep dasar Lean, Lean Thinking, customer value, value-added dan non-value-added activities, identifikasi dan eliminasi waste, 5S, Kaizen, PDCA, Value Stream Mapping (VSM), Standard Work, visual management, Kanban, Just-in-Time, Total Productive Maintenance (TPM), problem solving, Root Cause Analysis, Poka-Yoke, takt time, cycle time, process mapping, hingga Key Performance Indicators (KPI) Lean.

Program juga menekankan bagaimana Lean Management tidak hanya diterapkan pada proses produksi, tetapi dapat digunakan pada berbagai fungsi seperti administrasi, warehouse, procurement, supply chain, maintenance, customer service, finance, maupun proses bisnis lainnya.

Melalui kombinasi pembelajaran teori, diskusi, studi kasus, workshop, dan simulasi, peserta diharapkan mampu mengidentifikasi pemborosan, menganalisis akar permasalahan, merancang improvement, serta membangun sistem kerja yang lebih efektif, efisien, stabil, dan berorientasi pada pelanggan.

Tujuan TRAINING EFFICIENT LEAN MANAGEMENT 2026-2027

• Memahami konsep, prinsip, filosofi, dan tujuan Lean Management.
• Memahami Lean Thinking dan customer value.
• Mengidentifikasi value-added dan non-value-added activities.
• Memahami berbagai jenis waste dalam proses bisnis.
• Mengidentifikasi sumber pemborosan dalam proses kerja.
• Mengukur efisiensi dan efektivitas proses.
• Memahami konsep continuous improvement.
• Menerapkan PDCA dan Kaizen.
• Menerapkan metode 5S di lingkungan kerja.
• Membuat dan menggunakan Value Stream Mapping.
• Mengidentifikasi bottleneck dan process constraint.
• Mengurangi lead time dan cycle time.
• Meningkatkan process flow.
• Memahami konsep takt time.
• Memahami prinsip Just-in-Time.
• Memahami sistem Kanban dan pull system.
• Menerapkan Standard Work.
• Memahami Visual Management.
• Menggunakan Root Cause Analysis untuk menyelesaikan masalah.
• Menerapkan 5 Why dan Fishbone Diagram.
• Memahami Poka-Yoke atau error proofing.
• Memahami hubungan Lean dengan Quality Management.
• Memahami hubungan Lean dengan Total Productive Maintenance.
• Menentukan Lean KPI.
• Mengukur hasil improvement.
• Menyusun Lean improvement roadmap.
• Membangun budaya continuous improvement di organisasi.

Materi TRAINING EFFICIENT LEAN MANAGEMENT 2026-2027

Modul 1 – Fundamental Lean Management

• Pengertian Lean Management.
• Sejarah dan perkembangan Lean.
• Konsep Lean Thinking.
• Tujuan Lean Management.
• Prinsip dasar Lean.
• Customer value.
• Value creation.
• Value-added activities.
• Non-value-added activities.
• Necessary but non-value-added activities.
• Waste elimination.
• Continuous improvement.
• Flow dan pull.
• Perfection.
• Lean culture.
• Lean Management dalam organisasi modern.

Modul 2 – Lean Thinking & Customer Value

• Pengertian customer value.
• Identifikasi kebutuhan pelanggan.
• Voice of Customer.
• Customer requirements.
• Value definition.
• Value creation process.
• Value vs waste.
• Customer-focused process.
• Identifikasi aktivitas yang memberikan nilai.
• Identifikasi aktivitas yang tidak memberikan nilai.
• Value-based process improvement.

Modul 3 – The Eight Wastes

Peserta mempelajari identifikasi dan pengurangan berbagai bentuk waste, antara lain:

• Defects.
• Overproduction.
• Waiting.
• Non-utilized talent.
• Transportation.
• Inventory.
• Motion.
• Extra-processing.

Pembahasan meliputi:

• Karakteristik setiap waste.
• Penyebab waste.
• Dampak waste terhadap biaya.
• Dampak waste terhadap kualitas.
• Dampak waste terhadap lead time.
• Waste identification techniques.
• Waste walk.
• Gemba observation.
• Waste elimination strategy.

Modul 4 – Process Analysis

• Konsep process analysis.
• Process mapping.
• Process sequence.
• Process inputs dan outputs.
• Identifikasi bottleneck.
• Identifikasi process constraints.
• Cycle time.
• Lead time.
• Waiting time.
• Processing time.
• Queue time.
• Process efficiency.
• Process capacity.
• Process utilization.
• Identifikasi improvement opportunities.

Modul 5 – Value Stream Mapping (VSM)

• Pengertian Value Stream Mapping.
• Tujuan VSM.
• Current State Map.
• Future State Map.
• Value stream.
• Material flow.
• Information flow.
• Customer demand.
• Supplier process.
• Production process.
• Inventory points.
• Lead time.
• Cycle time.
• Takt time.
• Process lead time.
• Identifikasi bottleneck.
• Identifikasi waste melalui VSM.
• Penyusunan Future State.
• Studi kasus Value Stream Mapping.

Modul 6 – 5S Workplace Organization

• Pengertian 5S.
• Seiri – Sort.
• Seiton – Set in Order.
• Seiso – Shine.
• Seiketsu – Standardize.
• Shitsuke – Sustain.
• Tujuan penerapan 5S.
• Identifikasi unnecessary items.
• Workplace organization.
• Visual workplace.
• Standardisasi area kerja.
• 5S audit.
• 5S checklist.
• Visual control.
• Sustainability 5S.
• Studi kasus implementasi 5S.

Modul 7 – Kaizen & Continuous Improvement

• Pengertian Kaizen.
• Prinsip continuous improvement.
• Kaizen culture.
• Kaizen event.
• Small improvement.
• Employee involvement.
• Problem identification.
• Improvement opportunity.
• Kaizen implementation cycle.
• PDCA.
• Plan.
• Do.
• Check.
• Act.
• Standardization after improvement.
• Kaizen effectiveness measurement.

Modul 8 – PDCA Problem Solving

• Pengertian PDCA.
• Identifikasi masalah.
• Problem statement.
• Target improvement.
• Data collection.
• Analysis.
• Solution development.
• Implementation.
• Verification.
• Standardization.
• Continuous monitoring.
• PDCA case study.

Modul 9 – Standard Work

• Pengertian Standard Work.
• Tujuan standardisasi.
• Standard Work Combination.
• Standard Work Sequence.
• Standard Work in Process.
• Work instruction.
• Standard operating procedure.
• Cycle time standard.
• Takt-based work.
• Standardization untuk mengurangi variasi.
• Standard Work audit.
• Continuous improvement terhadap standard work.

Modul 10 – Takt Time, Cycle Time & Lead Time

• Pengertian takt time.
• Pengertian cycle time.
• Pengertian lead time.
• Perbedaan takt time dan cycle time.
• Customer demand.
• Available production time.
• Capacity analysis.
• Line balancing.
• Bottleneck identification.
• Waiting time reduction.
• Lead time reduction.
• Process synchronization.
• Studi kasus perhitungan takt time.

Modul 11 – Just-in-Time (JIT)

• Konsep Just-in-Time.
• Tujuan JIT.
• Pull production.
• Demand-driven process.
• Inventory reduction.
• Flow.
• Small lot production.
• Production leveling.
• Supplier coordination.
• JIT benefits.
• Risiko implementasi JIT.
• Persyaratan penerapan JIT.

Modul 12 – Kanban & Pull System

• Pengertian Kanban.
• Fungsi Kanban.
• Push vs Pull system.
• Kanban signal.
• Kanban card.
• Kanban quantity.
• Replenishment.
• Supermarket system.
• Inventory control.
• Visual pull system.
• Kanban implementation.
• Studi kasus Kanban.

Modul 13 – Visual Management

• Pengertian Visual Management.
• Tujuan visual control.
• Visual workplace.
• Visual indicators.
• Performance boards.
• Andon concept.
• Status visualization.
• Abnormality management.
• Visual standards.
• Visual KPI.
• Visual problem identification.
• Implementasi visual management.

Modul 14 – Problem Solving & Root Cause Analysis

• Problem-solving mindset.
• Problem identification.
• Problem definition.
• Data-based problem solving.
• 5 Why Analysis.
• Fishbone Diagram.
• Cause-and-effect analysis.
• Pareto Analysis.
• Stratification.
• Root Cause Analysis.
• Verification of root cause.
• Corrective action.
• Effectiveness verification.

Modul 15 – Poka-Yoke / Error Proofing

• Pengertian Poka-Yoke.
• Tujuan error proofing.
• Human error vs system error.
• Prevention vs detection.
• Poka-Yoke principles.
• Error prevention.
• Error detection.
• Visual error proofing.
• Process control.
• Quality at source.
• Contoh implementasi Poka-Yoke.

Modul 16 – Lean Quality Management

• Lean dan Quality.
• Quality at source.
• Defect prevention.
• First Time Right.
• First Pass Yield.
• Defect reduction.
• Rework reduction.
• Scrap reduction.
• Standardization.
• Process capability.
• Quality improvement.
• Integrasi Lean dan Quality Management.

Modul 17 – Lean Maintenance & TPM

• Konsep Lean Maintenance.
• Hubungan Lean dan maintenance.
• Total Productive Maintenance.
• Equipment effectiveness.
• Planned maintenance.
• Autonomous maintenance.
• Preventive maintenance.
• Predictive maintenance.
• Breakdown reduction.
• Downtime reduction.
• OEE – Overall Equipment Effectiveness.
• Availability.
• Performance.
• Quality.
• Improvement terhadap equipment losses.

Modul 18 – Inventory & Warehouse Lean

• Konsep Lean Inventory.
• Inventory waste.
• Excess inventory.
• Stockout.
• Inventory turnover.
• Warehouse flow.
• Material handling.
• Storage optimization.
• FIFO.
• Visual inventory control.
• Kanban inventory.
• Picking efficiency.
• Warehouse layout.
• Reduction of unnecessary movement.
• Lean warehouse improvement.

Modul 19 – Lean Supply Chain

• Lean Supply Chain Management.
• Supplier relationship.
• Supplier lead time.
• Procurement waste.
• Material flow.
• Information flow.
• Supplier performance.
• Delivery reliability.
• Inventory optimization.
• Demand management.
• Supply chain visibility.
• Collaboration dengan supplier.
• Lean logistics.

Modul 20 – Lean Office & Administrative Process

• Konsep Lean Office.
• Administrative waste.
• Information flow.
• Document flow.
• Approval process.
• Waiting time.
• Excess processing.
• Duplicate work.
• Data entry waste.
• Meeting waste.
• Email and communication waste.
• Process simplification.
• Digital workflow improvement.
• Lean service process.

Modul 21 – Lean KPI & Performance Measurement

• Konsep Lean KPI.
• Productivity.
• Efficiency.
• Effectiveness.
• Lead time.
• Cycle time.
• Throughput.
• First Pass Yield.
• Defect rate.
• Scrap rate.
• Rework rate.
• On-Time Delivery.
• Inventory turnover.
• OEE.
• Overall process efficiency.
• KPI dashboard.
• Before-and-after improvement measurement.

Modul 22 – Lean Leadership & Culture

• Peran leadership dalam Lean.
• Lean leadership principles.
• Management commitment.
• Employee engagement.
• Empowerment.
• Gemba leadership.
• Coaching.
• Problem-solving culture.
• Accountability.
• Communication.
• Lean mindset.
• Building continuous improvement culture.
• Sustainability of Lean implementation.

Modul 23 – Lean Implementation Roadmap

• Menentukan Lean vision.
• Menentukan baseline.
• Process assessment.
• Identifikasi priority area.
• Waste assessment.
• Penentuan improvement priorities.
• Kaizen planning.
• Improvement project selection.
• Resource planning.
• Implementation timeline.
• KPI monitoring.
• Sustainability plan.
• Lean maturity assessment.
• Continuous improvement roadmap.

Modul 24 – Lean Simulation & Workshop

Peserta melakukan latihan dan simulasi yang dapat meliputi:

• Identifikasi 8 waste.
• Waste walk.
• Process mapping.
• Value Stream Mapping.
• Current State Mapping.
• Future State Mapping.
• Takt time calculation.
• Cycle time analysis.
• Bottleneck analysis.
• 5S assessment.
• Kaizen exercise.
• 5 Why analysis.
• Fishbone analysis.
• Poka-Yoke design.
• Kanban simulation.
• Lean KPI calculation.
• Improvement project planning.