School of Lean

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Understand and employ the right lean tools to solve real problems, using content created by real practitioners.

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Continuously improve your organization with a solid foundation of lean knowledge.

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School of Lean Contents

The School of Lean consists of:

  • 251 videos, 91 quizzes, 173 downloads
  • Subscribers also receive access to Gemba Live!™
     
  • The first video of each course can be watched here.
  • Request a 3 Day Trial to see everything!

Introductory Topics

In this section we're introduced to lean and the fundamental concepts of continuous improvement.

  1. Introduction to Lean (14:42)

    A quick introduction to the philosophy, history, and tools of lean.
  2. Ten Commandments of Continuous Improvement (7:26)

    The necessary components to create a continuous improvement culture.
  3. Developing Strategies to Sustain Operational Excellence (18:06)

    Ron Pereira, co-founder of Gemba Academy, discusses how to develop strategies to sustain operational excellence in a presentation to a group of executives.

5S Workplace Productivity

In the 5S Workplace Productivity Course you and your entire organization will learn exactly what 5S is, where it originated from, and why it’s far more than a housekeeping initiative. And most importantly, you will learn, step by step, how to start or possibly enhance your own corporate wide 5S program.

  1. 5S Overview (9:55)

    Sheds some insight into what 5S is as well as the steps to implementing 5S.
  2. Sort (4:36)

    The first step. Learn exactly what sorting is and how to go about it.
  3. Red Tagging (7:59)

    By the end of this module you will know exactly how to go about the “red tagging” process no matter if you are a machinist, accountant, or nurse.
  4. Straighten (10:14)

    This important step is far more than "lining things up in straight rows." By the end of this module you'll understand why.
  5. Sweep (7:03)

    By the end of this module you'll understand why the true mantra of 5S is actually “to sweep is to not clean!”
  6. Standardize (8:32)

    By the end of this module you'll know how to standardize your work area using tools like safety crosses and shadow boards.
  7. Sustain (9:47)

    By the end of this module you’ll understand why a taut rope perfectly describes the sustain step of 5S.
  8. 5S Numbers Game (8:09)

    Learn how powerful 5S is by playing a fun game designed to open the eyes of the lean skeptics.
  9. Skills Matrix (13:46)

    Learn why a skill matrix is an essential tool for any organization serious about visual management and succession planning.

Dealing With the Seven Deadly Wastes

You may already know what the 7 deadly wastes are… but do you know how to defeat them? We’ll show you how as we take our cameras inside Ram Technologies, a custom foam fabricator located in Mukilteo, Washington to witness each waste in action.

  1. Seven Wastes Overview (10:59)

    Learn what the seven wastes are and why they are so deadly to your organization.
  2. Stand in the Circle (4:56)

    Popularized by Taiichi Ohno, learning to “stand in the circle” the right way is a must for all lean practitioners.
  3. Waste of Defects (8:22)

    Learn what the waste of defect is, what causes it, and what lean tools are best suited to battle it.
  4. Waste of Inventory (8:06)

    In these tough economic times, managing inventory is extremely important. Learn how to calculate cycle stock, buffer stock, and safety stock in this module.
  5. Waste of Processing (5:39)

    The hardest waste to see and defeat. Learn what processing is and what you must do to eliminate it.
  6. Waste of Waiting (4:19)

    The most “annoying” waste of all, and arguable one of the most devastating to service related companies. Learn how to squash waiting once and for all.
  7. Waste of Motion (6:24)

    The mother of all “productivity” wastes. Learn a 5 step process for defeating motion once and for all in this module.
  8. Waste of Transportation (7:18)

    Learn why forklifts and pallet jacks may be costing you far more than you realize in this module.
  9. Waste of Overproduction (6:31)

    The “mother of all wastes.” Learn exactly how to defeat the beast that is overproduction in this module.

The Kaizen Way Course

Translated the word kaizen means to “change for the better”. In The Kaizen Way you’ll learn exactly what kaizen is and how it’s helping organizations in industries such as manufacturing, office environments, and healthcare reduce costs and increase profits without resorting to massive layoffs. In fact, during The Kaizen Way you’ll hear how one company managed to increase net profits by close to 25% even though their sales were down by 25% the same year!

  1. Kaizen Overview (9:54)

    Learn what kaizen is while also watching kaizen in action as we venture into the kitchen (no toast involved).
  2. The Kaizen Event (11:17)

    Learn what the powerful kaizen event is as well as what the Gemba Academy 5 day recommended kaizen event roadmap is.
  3. Kaizen Success Story (9:34)

    We take a break from our traditional teaching lessons in order to hear Federal Heath’s kaizen success story. Even with reduced 2009 revenues, Federal Heath actually increased profits in the 20%-25% range. Hear their story in this video.
  4. Real Life Kaizen (14:02)

    We continue our discussion with Rick Foreman of Federal Heath as we hear of several specific kaizen improvements the Federal Heath team has recently implemented.
  5. System vs. Point Kaizen (2:37)

    Learn the difference between system kaizen and point kaizen and why it’s so important they work together in harmony for long term success.
  6. Kaizen Event Roles (4:09)

    In this module you'll learn what the key kaizen event roles are as we prepare to learn how to prepare and execute a world class kaizen event.
  7. Preparing for the Kaizen Event (7:38)

    Learn how to prepare for the kaizen event using the Gemba Academy kaizen event timeline checklist.
  8. The Kaizen Event Week (6:34)

    Learn what to expect during the kaizen event week including what to do when facing negative attitudes early in the week.
  9. Post Kaizen Event Activities (3:25)

    Learn the activities that should follow the actual kaizen event week.
  10. Simple Kaizen Part 1 (9:30)

    Mike Wroblewski, a senior Consultant for Gemba Consulting, explains the "Simple Kaizen" approach to suggestion systems. Mike explains, in great detail, how to move beyond the "suggestion box" while also explaining how one company has been able to generate and implement 4,998 employee suggestions in a single year.
  11. Simple Kaizen Part 2 (9:24)

    A continuation of the Simple Kaizen Part 1 module.
  12. The Kaizen Coach (5:17)

    Mike Wroblewski offers advice on how a Kaizen Coach can get the most out of their kaizen team. With many years of practical experience as a Kaizen Coach, the advice Mike offers will add tremendous value no matter if you are new to Kaizen or an experienced practitioner.
  13. D.L. Martin Kaizen Event Summary (14:43)

    Hear a detailed explanation of how D.L. Martin Co. executed an actual 5S and Layout kaizen event. During this module you’ll see how they train their employees, how they 5S an area, and how they actually piloted a one piece flow simulation in preparation for a follow-up kaizen event. Finally, during this video you’ll hear (and see) how they prepare and execute the kaizen event report out for senior management.

Transforming Your Value Streams

In this course you and your entire organization will learn how to transform your value streams using lean tools and principles such as value stream mapping, takt time, kanban, error proofing, and heijunka/production leveling. During this course you will follow a fictitious bird house manufacturing company as they journey through the process of creating both current and future state value stream maps along with an action plan.

  1. Value Stream Overview (13:24)

    Sheds some insight into what value stream mapping is as well as the steps to value stream mapping.
  2. Product Family Selection (7:12)

    Learn how to use product routing (PR) and product quantity (PQ) analysis.
  3. VSM Shapes & Icons (6:35)

    Get acquainted with the most common value stream mapping shapes and icons.
  4. Calculating Takt Time (4:52)

    Learn exactly what takt time is and how to calculate it.
  5. Current State Part 1 (12:57)

    Creating current state value stream maps takes practice. Arm yourself with the knowledge needed to create your own!
  6. Current State Part 2 (12:06)

    Learn how Treetop Incorporated creates their own current state value stream map.
  7. Continuous Flow (11:02)

    Learn how to make value flow one piece at a time.
  8. Balancing Cycle Time & Takt Time (10:16)

    Learn how to balance cycle time and takt time in such a way as to flow in a continuous manner.
  9. Downstream Pull (13:33)

    Learn the difference between push and pull. Also, learn what kanban are and how to use them.
  10. Production Leveling (8:36)

    Before kanban can work we must level production. In this module you will earn what heijunka is.
  11. The Future State - Part 1 (11:52)

    Pull it all together in with the future state value stream map.
  12. The Future State - Part 2 (11:52)

    Watch how Treetop, Incorporated plans to transform from a traditional mass producer to a lean producer.
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  13. Transactional or Office Value Stream Mapping (16:13)

    More information on applying value stream mapping to transactional or office environments.
  14. Value Stream Mapping Resources (3:57)

    Resources to support value stream mapping activities.
  15. One Piece Flow Simulation (11:38)

    Learn how one piece flow works with this envelope stuffing exercise.
  16. Transactional Detailed Process Mapping - 1 (15:15)

    Learn a simple, but extremely powerful, method for mapping transactional processes.
  17. Transactional Detailed Process Mapping - 2 (9:00)

    Learn a simple, but extremely powerful, method for mapping transactional processes.

Practical Problem Solving Course

We can say that the entire lean manufacturing system is a result of decades of continuous problem solving by all of the people and companies who have contributed to the development of lean systems. The Gemba Academy Practical Problem Solving course explains the exact 8 step problem solving process used by these lean exemplars around the world. In this course you’ll learn why PDCA is much more than 4 simple steps while also learning how to create and use statistical tools like control charts, Pareto charts, and scatter plots.

  1. PPS Overview (10:29)

    An overview of the 8 steps to Practical Problem Solving.
  2. PDCA (6:28)

    An overview of the PDCA problem solving process.
  3. Treetop, Inc. (2:45)

    Explains the fictitous case study "problem" that will be addressed during the rest of the course.
  4. Step 1: Clarify the Problem (10:27)

    Learn how clarify problems as well as how to write strong problem statements.
  5. Introduction to SigmaXL (5:30)

    Creating various statistical graphs and charts in Microsoft Excel is extremely easy with SigmaXL, an addon to MS Excel. Learn what it is and how to download it in this video.
  6. Creating Run Charts with SigmaXL (2:57)

    Learn how to quickly create Run Charts using SigmaXL.
  7. Creating Control Charts with SigmaXL (4:01)

    Learn how to quickly create Control Charts using SigmaXL.
  8. Step 2: Break Down the Problem (12:47)

    Learn how to break vague problems down using tools like Pareto charts and Tree Diagrams.
  9. Creating Dot Plots with SigmaXL (3:32)

    Learn how to quickly create Dot Plots using SigmaXL.
  10. Creating Pareto Charts with SigmaXL (3:08)

    Learn how to quickly create Pareto Charts using SigmaXL.
  11. Step 3: Set a Target (8:04)

    Learn how to set SMART targets enabling success in future steps.
  12. Step 4: Analyze Root Causes (5:33)

    An introduction to how to go about analyzing root causes.
  13. Fishbone Diagram Explained (10:32)

    Learn exactly what the fishbone diagram is as well as how to create one.
  14. Five Why Explained (7:58)

    Learn what 5 Why Analysis is as well as how to leverage it to identify root causes.
  15. Treetop Gets to the Root Causes (7:05)

    Watch how Treetop Incorporated gets to the root causes of the problems plaguing them.
  16. Creating Scatter Plots with Sigma XL (3:40)

    Learn how to quickly create Scatter Plots using SigmaXL.
  17. Step 5: Develop Countermeasures (9:22)

    Learn how to develop countermeasures as well as how to conduct brainstorming sessions the correct way.
  18. Step 6: See Countermeasures Through (6:10)

    In this module you will learn how to implement countermeasures, even in the face of resistance.
  19. Step 7: Evaluate the Process and Results (7:13)

    Learn how to determine if your countermeasures were successful after they have been implemented.
  20. Step 8: Standardize Success and Learn from Failures (9:25)

    Learn what Yokoten and Hansei are and why they are a critical aspect of the Practical Problem Solving methodology

The Seven Quality Control Tools Course

We can say that the entire lean manufacturing system is a result of decades of continuous problem solving by all of the people and companies who have contributed to the development of lean systems. The Gemba Academy Seven Quality Control Tools course explains the exact 7 tools used by quality control experts. No matter if you work in a factory making “widgets” or in a hospital taking care of patients, the concepts taught in this course will forever change the way you use statistical methods to analyze and control quality. In this course you’ll learn the seven key quality control tools while also learning how to create and use statistical tools like control charts, Pareto charts, and scatter plots.

  1. 7QC Overview (8:15)

    Learn what Quality Control is as well as what the 7QC Tools are.
  2. QC Tool 1: The Graph (4:52)

    Learn about 5 powerful graphs, what they are and when to use them.
  3. Bar Charts (4:10)

    Learn how to create bar charts in MS Excel.
  4. Broken Line Graphs (3:39)

    Learn how to create broken line graphs in MS Excel.
  5. Pie Charts (4:19)

    Learn how to create pie charts in MS Excel.
  6. Band Graphs (4:24)

    Learn how to create band graphs in MS Excel.
  7. Radar Charts (3:40)

    Learn how to create radar charts in MS Excel.
  8. QC Tool 2: The Check Sheet (4:44)

    Learn how to leverage this simple, but powerful tool in both manufacturing and front office situations.
  9. QC Tool 3: The Pareto Chart (4:47)

    Learn the history and application of arguably the single most important problem solving tool available.
  10. Creating a Pareto Chart in Sigma XL (1:57)

    Learn exactly how to create a Pareto chart in Sigma XL.
  11. QC Tool 4: The Cause & Effect Diagram (8:59)

    Commonly referred to as the Fishbone, the Cause & Effect Diagram is extremely helpful at identifying root causes. Learn how to leverage this tool in this module.
  12. Basic Statistics (5:00)

    Learn what statistics are and how they can help us when leveraged correctly. You’ll also learn what descriptive statistics are as we prepare to dive deeper in the coming modules.
  13. Measures of Central Tendency (5:14)

    Learn what the 3 measures of central tendency are as well as how to calculate them by hand.
  14. Measures of Dispersion (6:00)

    Learn what the 3 measures of dispersion are as well as how to calculate them by hand.
  15. Generating Descriptive Statistics (6:32)

    Learn how to quickly generate descriptive statistics using either MS Excel or Sigma XL.
  16. QC Tool 5: The Scatter Diagram (6:12)

    Learn what the Scatter Diagram is and how to create one. You will also learn about Simple Linear Statistics such as R Squared and how to build predictive statistical models.
  17. Creating Scatter Diagrams and Regression Statistics (1:46)

    Learn exactly how to create Scatter Diagrams while also generating Simple Linear Regression statistics such as R Squared and Predictive models.
  18. QC Tool 6: The Histogram (5:25)

    Learn what the histogram is and how it can help you better understand your front office or manufacturing related process.
  19. Calculating Cp and Cpk (5:57)

    In this module you'll learn what Cp and Cpk are as well as how to calculate them.
  20. Creating Histograms & Cp / Cpk Statistics (8:50)

    Learn how to easily generate histograms as well as Cp and Cpk statistics using Sigma XL. It really is as easy as 1, 2, 3.
  21. QC Tool 7: The Control Chart (3:57)

    Learn what the control chart is as well as the difference between common and special cause variation.
  22. Creating Control Charts in Sigma XL (5:55)

    Learn how to quickly generate both Individuals and Individuals + Moving Range Control Charts using Sigma XL.
  23. MSA Overview (6:31)

    Learn what a Measurement System Analysis is and why it’s so important for anyone attempting to improve a process!
  24. The Attribute Data MSA (4:15)

    Learn how to plan and conduct an attribute data MSA.
  25. Attribute Data MSA Analysis in SigmaXL (8:35)

    Learn how to analyze the results of an Attribute MSA using Sigma XL.
  26. The Variable Data MSA (3:27)

    Learn how to plan and conduct a variable data MSA.
  27. Variable Data MSA Analysis in SigmaXL (10:43)

    Learn how to analyze the results of a variable data MSA using Sigma XL.

A3 Thinking

Explore how A3 thinking can positively impact any organization in any industry. View real-world case studies and hear testimonials from leaders that have benefited from A3s.

  1. A3 Thinking Overview (9:19)

    An overview of the A3 Thinking course.
  2. Revisiting the Big Problem at Treetop (5:02)

    Understand the Big Problem at Treetop, Inc. and use Practical Problem Solving to clarify the problem and break it down into manageable pieces. Prepare to use the A3.
  3. Using the A3 Report at Treetop (6:47)

    Learn how an A3 can be used to document the PPS process. We'll follow one Treetop team's PPS journey.
  4. Leveraging A3s During Strategic Planning (8:31)

    Learn how A3s can be used during the Hoshin Planning Process and see another A3 layout.
  5. A3 Report Examples (7:44)

    See 3 different A3 report examples from real companies.
  6. The Proposal A3 (16:07)

    In this interview, Michael Lombard, Director of Operational Excellence at a hospital, talks about how his organization used an A3 for a very important initiative.
  7. Chris Schrandt on A3 Thinking (6:30)

    A former quality manager at Toyota Motor Corporation, provides an overview on A3 Thinking.
  8. Chris Schrandt Interview (12:47)

    Ron talks with Chris Schrandt about A3 Thinking while at a historic lighthouse in Mukilteo, WA.
  9. Practical A3 Tips and Advice (5:11)

    Learn some practical A3 tips to help you get started.

Just in Time Course

Gemba Academy is proud to present this "Just in Time" video series which was originally produced by our consulting partners at the Kaizen Institute. The main topic of this video series is Kaizen and Just in Time which was the original phrase used to describe what we now call Lean Manufacturing. Throughout this series you'll see many examples of lean principles in action at companies such as Wiremold and Giorgio Foods. You'll also receive an excellent review of topics such as One Piece Flow, Takt Time, U shaped cells, Production Leveling, Kanban, 5S, the Visual Workplace, and Standard Work.

  1. JIT Introduction (1:36)

    Ron Pereira introduces this video series.
  2. JIT Pays - Part 1 (10:14)

    In this first video you'll learn what Kaizen and Just in Time (Lean Thinking) is all about. You'll also hear Art Byrne, one of the original lean thinking pioneers of our time, explain how JIT was positively impacting Wiremold.
  3. JIT Pays - Part 2 (9:41)

    Learn how Just in Time can drastically reduce leadtimes. You'll also hear the story of the Japanese company Yasda Precision Tools K.K. and how they leveraged JIT in order to not have to lay off employees when faced with decreased demand. You'll also meet the good folks at Giorgio Foods as they explain the benefits of Kaizen to their world class organization.
  4. JIT Pays - Part 3 (14:31)

    You'll see and hear from Japanese company Matsushita Electric Works, LTD in this video. You'll also see a superb example of U shaped cells in action.
  5. JIT in Action - Part 1 (12:46)

    In this video we learn the difference between value and waste, referred to as muda in the Japanese language. You'll also see some superb real life examples of the 7 wastes in action.
  6. JIT in Action - Part 2 (10:59)

    We continue to see examples of waste in action while also seeing how JIT and Lean principles can effectively eliminate waste resulting in a dramatic productivity increase.
  7. JIT Technologies - Part 1 (9:46)

    In this first video the JIT Technologies topic we learn about the difference between Push and Pull production. We also have a thorough explanation of what Takt time is and how it is used to support one piece flow.
  8. JIT Technologies - Part 2 (10:38)

    An explanation of how Skill display boards work is offered. We also learn more about U shaped cells including how Giorgio Foods converted a mushroom canning process from a traditional straight line to a U shaped cell. An overview on Production Leveling (Heijunka) is also provided.
  9. JIT Technologies - Part 3 (2:30)

    A discussion on Setup Kaizen or Quick Changeover is provided in this video including explanations of the difference between internal and external setups.
  10. JIT Technologies - Part 4 (4:03)

    Without Standards there can be no Kaizen. As such we learn what Standard Work is and why it\'s so important to Lean Production.
  11. JIT Technologies - Part 5 (5:00)

    You will learn how kanban supports JIT and Lean Production while also seeing kanban in action inside an actual factory.
  12. JIT Technologies - Part 6 (9:22)

    You will learn how 5S and a Visual Workplace are at the foundation of Kaizen. You’ll also learn how to extend your Kaizen efforts across your entire organization.

The Kanban Course

In this course focused on introducing the powerful topic of kanban, Ron Pereira explains what kanban are and how to implement some of the most popular kanban systems into a production environment. You'll also receive access to kanban calculators that make the sometimes intimidating math involved simple and easy to handle. Finally, Ron will explain what needs to be in place to ensure kanban success as well as the 6 rules to follow to ensure your kanban system not only survives, but thrives over time.

  1. Kanban Overview (7:11)

    In this module you'll learn what kanban are and how they can be used to control the production and movement within any facility. You'll also learn what many of the most common kanban systems are including the simple, but powerful, 2 bin kanban system.
  2. 2 Card Kanban System (13:07)

    You will learn how the popular 2 card kanban system operates through a detailed simulation where you will watch production and withdrawal kanban flow through a mixed model production process. Not to be confused with the 2 bin system, the 2 card system is powerful and, used properly, will change the way your factory operates.
  3. 2 Card Kanban Calculations (5:07)

    In this module you will learn how to calculate the number of Production and Withdrawal Kanban needed with the 2 Card Kanban System. We'll also introduce an Excel based Kanban Calculator that makes these calculations unbelievably simple and fast.
  4. Kanban in Batch Production (5:33)

    While our goal as Lean Practitioners is to flow material one piece at a time there may be situations where you must produce some products in a batch. The good news is this sort of system can still be kept under control using a Signal Kanban system. In this module you will learn how this works through another simulation where you will watch a Signal Kanban system in action.
  5. Calculating Signal Kanban Quantities (2:55)

    Ron Pereira explains how to calculate the number of containers required to operate a Signal Kanban System. Ron will also show how to quickly determine exactly where to position the Triangle/Signal Kanban.
  6. The 6 Kanban Prerequisites (8:16)

    In order to succeed with Kanban there are 6 prerequisites that must be in place. By the end of this module you\'ll know what they are.
  7. The 6 Golden Rules of Kanban (2:16)

    To wrap things up you'll learn what are called the 6 Golden Rules of Kanban. If you follow these rules your chances of Kanban success will radically improve.
  8. One Piece Flow Simulation (11:38)

    Learn how one piece flow works with this envelope stuffing exercise.

Quick Changeover - The SMED System

Learn how to radically reduce machine changeovers using the SMED (Single Minute Exchange of Dies) system while watching Ram Technologies work through an actual SMED kaizen event that results in a 66% reduction in changeover time! Please plan approximately 30 minutes of learning time for each module, including watching the video, taking the quiz, and reviewing supporting documents.

  1. Overview Part 1 (10:30)

    Learn what Quick Changeover and SMED are and why they are extremely important lean concepts for producers of any product or service.
  2. Overview Part 2 (7:48)

    Learn what the 8 steps to Quick Changeover are and how to go about them.
  3. Document Reality Part 1 (8:48)

    Learn how to "capture" or document reality using tools like the video camera.
  4. Changeover Part 1 (16:12)

    Watch Dawn, from Ram Technologies, complete an actual changeover of a press. This changeover will serve as the “before improvement” video for the rest of the course.
  5. Changeover Part 2 (16:02)

    Part 2 of the Ram Changeover.
  6. Document Reality Part 2 (6:26)

    Learn how to use the SMED analysis sheet by documenting what we witnessed in the “before improvement” Ram changeover video.
  7. Homework (2:19)

    It's time to practice as we ask you how you’d improve the changeover using the principles you’ve already learned at Gemba Academy.
  8. Separate and Shift Internal to External (9:04)

    Learn how to transfer what was thought to be internal steps to external steps which radically reduces machine downtime.
  9. Streamline External Tasks (6:45)

    Learn how to streamline external tasks while also identifying internal tasks that can be done in parallel much like F1 or NASCAR pit crews do.
  10. Streamline Internal Tasks (9:49)

    Learn how to streamline internal tasks by eliminating waste like adjustments and motion.
  11. Document the New Standard (7:50)

    Learn how to practice and properly document the new and improved changeover.
  12. Ram Changeover After Improvements (11:29)

    Watch the new and improved changeover at Ram Technologies (66% improvement).
  13. Mike Wroblewski Interview (8:33)

    In this supplemental module you'll hear from Mike Wroblewski. Mike learned the SMED System from Shigeo Shingo, the man responsible for developing the SMED approach. During this interview Mike explains how Mr. Shingo went about teaching his students the SMED System, including how he used to explain how buying bananas is an excellent example of lean thinking. How can this be? Mike tells all in this module.

Standard Work Course

In this course we cover, in great detail, the 4 types of Standard Work that apply to any type of work or industry. You see, contrary to what some think… Standard Work applies to any type of activity no matter if you produce widgets in a factory or do so-called creative work in an office environment.

  1. Standardization (4:51)

    Learn what both Standards and Standardization are and why they are crucial to long term continuous improvement success.
  2. Prerequisites (2:43)

    There are several prerequisites that must be in place before attempting Standard Work. If you miss these failure is almost certain.
  3. Introduction (6:37)

    Learn what the four types of Standard Work are and how they apply to any organization no matter if you build cars on an assembly or do so-called creative work inside a cubicle.
  4. 3 Elements (6:10)

    Learn what the 3 elements of Standard Work are and how to apply them properly.
  5. Process Capacity Tool (7:43)

    Learn how to identify bottlenecks and maximum capacity with the Standard Work Tool.
  6. Standard Work Combination Sheet (6:50)

    Learn how to create one of the most misunderstood and misused Standard Work templates in this module.
  7. Standard Work Sheet (5:57)

    Learn how to document the "dance steps" of associates working in the same cell or work area.
  8. Standard Work Instruction Sheet (3:10)

    Learn how to tie multiple Standard Work documents into one easy to understand form that can be used to train new associates.
  9. Standard WIP (7:00)

    Learn how to calculate Standard WIP when faced with things such as automatic cycle machines and external supplier processes that require some batch processing.
  10. Lead Time (4:46)

    Learn an extremely accurate lead time measurement for organization’s fully immersed in Standard Work.
  11. Time Observation Sheet (8:37)

    Arguably the most powerful Industrial Engineering tool available... when used correctly, the Time Observation Sheet will become the backbone of your Standard Work implementation.
  12. How to Draw a Pig (9:13)

    We take a break from our traditional teaching lessons as we have some fun drawing a pig, with and without Standard Work. This module is best viewed with a group of people.
  13. Step by Step (11:11)

    In this module we tie all of the previous Standard Work tools together in a step by step manner ensuring we have a solid understanding of Type 1 Standard Work before transitioning to Type 2 Standard Work.
  14. Mixed Model Standard Work Introduction (3:51)

    We introduce how Standard Work applies to non repetitive, mixed model, applications while also introducing the mixed model case study we will follow in the coming modules.
  15. Mixed Model - Balance Work Among Operators (6:38)

    We introduce the Timer Pro Software (Free Trial to Full Version Available to Gemba Academy students) while also learning how to balance work among multiple operators.
  16. Mixed Model - Balance Cycle & Takt Time (7:31)

    We now learn how to easily balance cycle time to takt takt across multiple mixed models.
  17. Mixed Model - The Yamazumi Chart (4:09)

    We now learn how to send our balanced work to an extremely powerful lean tool called a Yamazumi Chart.
  18. Mixed Model - Creating Combination Sheets (3:59)

    Learn how to create multiple Standard Work Combination Sheets in seconds. Creating Standard Work doesn’t get any easier than this!
  19. Transactional Standard Work (4:19)

    Learn how to principles of Standard Work apply to non manufacturing environments such as in the office.
  20. Jon Miller on Standard Work (17:49)

    Jon Miller, Co-Founder of Gemba Academy and co-author of Creating a Kaizen Culture, sits down with Ron Pereira and addresses how to work with Standard Work when dealing with non repetitive processes. They also discuss the model line concept used by many lean thinking organizations.

Built In Quality

In this course focused on Built in Quality (BIQ) Chris Schrandt - a former Quality Engineering Manager at the Toyota Georgetown, KY plant - delivers a live workshop to a room full of lean thinkers at the Peterbilt Manufacturing Facility.

  1. Introduction (9:54)

    Chris Schrandt introduces himself and explains his background as a Toyota and GM Quality Manager. Chris also introduces the 4 different sections of the workshop.
  2. Definition of Built in Quality (12:51)

    Chris defines Built in Quality and explains how it ties in with the so-called "House of Toyota." Chris also explains the 3 M's - Muda, Muri, and Mura. Finally, Chris offers an overview of the 7 wastes of a process.
  3. Key Paradigms (14:56)

    We learn about some key paradigms all lean and quality conscious thinkers must be aware of.
  4. Five Levels of Quality (7:59)

    Chris introduces the 5 different levels of Quality within any organization.
  5. Prevention, Jidoka, Detection (8:25)

    Chris introduces the important topics of Prevention, Jidoka, and Detection.
  6. Organization and Poka Yoke (13:54)

    Chris offers a suggestion for the layout of a Quality Department Organization while also explaining the 4 roles of Quality Confirmation. Finally, we learn what Poka Yoke - or error proofing - is and more importantly isn't.
  7. Andons (13:26)

    In this video we learn about the Andon and Alarm escalation system including the role of team leaders when an issue is brought to their attention. Chris also explains the concept of defect containment as it relates to the Quality Organization.
  8. Quality Gates (7:22)

    Chris explains the concept of the Quality Gate. He also talks about the difference between a defect and repair.
  9. Supporting Tools (15:11)

    We learn about several BIQ Supporting tools including 5S, Visual Management, Teams, Just in Time Production (JIT), and Leader Standard Work.
  10. Problem Solving (15:19)

    In this video Chris introduces the topic of Problem Solving including the Quality Funnel, the 8 Steps to Problem Solving, and how to create a good Problem Statement.
  11. SMART Goals (14:19)

    Chris continues the Problem Statement discussion while also introducing the concept of how to set SMART goals. Chris also spends time explaining the 5 Why process including how to use the "therefore test" to ensure your analysis was sound.
  12. A3 and Wrap Up (14:00)

    Chris introduces the A3 document through a fun example of how to apply PDCA to your teenage daughter's first date. Finally, Chris wraps the course up by summarizing the importance of BIQ to the organization.

3P Production Preparation Process

In this course, which was filmed in front of a live audience, Mike Wroblewski a senior consultant for the Kaizen Institute, discusses 3P (Production Preparation Process) as it relates to the design of a new healthcare facility such as a hospital.

  1. Overview (12:39)

    An overview of the 3P Production Preparation Process course.
  2. Who is Our Customer? (9:03)

    Before 3P can happen we must understand who the customer is and what they expect.
  3. The 7 Flows of Healthcare (9:47)

    You will learn what the 7 Flows of Healthcare are and how they play a vital role in the 3P process.
  4. The 3P Steps (8:04)

    Mike Wroblewski explains what the steps of the 3P process while continuing to discuss the importance of understanding customer requirements.
  5. Collecting Data (10:14)

    In this module we learn how to collect data at the gemba, or the place the work is done.
  6. Collaborative Care (7:05)

    Learn the importance of collaborative care while also learning how to optimize the whole process and not just pieces of the process.
  7. Examples from Nature (6:10)

    In this module we learn how to look to nature for answers. Mike shares examples ranging from the way velcro was discovered to way clam shells influenced the design of casket hinges.
  8. Moonshining (8:18)

    Mike explains the so-called Moonshining process including where it came from as well as how to go about the moonshining process with your 3P team.
  9. Mockups (9:51)

    Mike explains the powerful process of using mockups to simulate new layouts before spending any money.
  10. Gap Analysis (11:28)

    Performing gap analysis, including how to deal with the idea that more space is the answer, is covered in this module.
  11. 3P Wrap-Up (8:05)

    Some final thoughts, including the importance of always being curious during the 3P process are covered in this module.

Total Productive Maintenance

In this pre-recorded, live training seminar shot at the Peterbilt Manufacturing Training Center in Denton, TX, Mike Wroblewski, a senior lean consultant from Gemba Consulting and the Kaizen Institute explains why Total Productive Maintenance (TPM) is not optional for lean thinking companies who rely on machines and equipment to satisfy customer demand. During this course Mikes explains what TPM is, and isn’t, while also covering important topics such as the 6 Big Losses and how to measure them using the extremely powerful Overall Equipment Effectiveness (OEE) metric.

  1. Overview (5:38)

    Ron Pereira offers an overview of what TPM is while also explaining the "live" format of this TPM course.
  2. Introduction (8:39)

    Mike Wroblewski explains what TPM is while also sharing the benefits of a robust TPM program.
  3. Are You Neglecting Your Equipment? (9:57)

    Mike explains what the lack of a TPM program can lead to by sharing real life examples of poortly maintained equipment.
  4. 6 Big Losses & OEE (9:54)

    Mike explains what the 6 Big Losses are and how to measure them using one of the most powerful lean metrics available - Overall Equipment Effectiveness - or OEE for short.
  5. The 4 TPM Phases (8:32)

    Mike explains what the 4 TPM Phases are by walking through an actual example from a past TPM kaizen event.
  6. Autonomous Maintenance (12:23)

    Learn how to actively engage operators in the maintenance process via a process called Autonomous Maintenance.
  7. Planning, Spare Parts, & Training (8:22)

    In the final video Mike discusses the TPM Planning process, spare parts programs, and training.

Gemba Glossary

The Gemba Glossary series provides a very short description, history, and application of key lean concepts.

  1. 5S (1:48)

    The short history, definition, and application of 5S.
  2. Seven Wastes (7W) (2:37)

    The short history, definition, and application of the seven wastes.
  3. Gemba (1:02)

    The short history, definition, and application of the gemba.
  4. 5 Why (1:55)

    The short history, definition, and application of the 5 Why concept.
  5. Value Stream (2:11)

    The short history, definition, and application of the Value Stream concept.
  6. Value Stream Mapping (2:04)

    The short history, definition, and application of the Value Stream Mapping concept.

Lean Lingo Explained Course

Brad Schmidt, Managing Partner of Gemba Japan, explains the roots of several of the most popular lean terms. As you'll soon realize, Brad loves to talk, smile, and have fun. And the fact he speaks and writes Japanese definitely helps!

  1. Kaizen (4:33)

    Learn why kaizen actually means so much more than continuous improvement.
  2. Muda (3:34)

    Learn what a horse has to do with the definition of muda.
  3. Muri (2:13)

    Learn the historical roots of muri.
  4. Gemba (4:11)

    What a great name for a company! Learn the roots of this popular lean term.
  5. Jidoka (5:07)

    Learn the real meaning of autonomation.
  6. Hansei (3:32)

    This word means much more than reflection. Learn why in this video.
  7. Hoshin Kanri (3:33)

    Learn what a tube and logic have to do with Hoshin Kanri.
  8. Poka Yoke (4:16)

    Did you know this term was originally called Baka Yoke? You’ll know why after watching this video.
  9. Kanban (3:57)

    Learn the roots of an extremely popular lean word and tool.
  10. Heijunka (3:24)

    Probably the most mispronounced lean term of all time! You’ll learn what heijunka is and how to say it in this video.
  11. Toyota, Honda, and Mazda (2:30)

    Learn what rice paddies have to do with some of the largest companies in the world.
  12. Should We Use Japanese Terms? (1:16)

    It's an age old, and often heated, debate. Learn Brad’s take on this question in this video.

Kaizen Leadership

In this series of videos the original Lean Guru, Mr. Masaaki Imai, discusses the topic of Kaizen Leadership.

  1. Part 1 (7:22)

    Mr. Imai explains what the 3 most important requirements for lean success are as well as introduces a new lean term called "FSL"
  2. Part 2 (8:45)

    Mr. Imai explains the difference between top management commitment and top management involvement. Mr. Imai also shares a new definition of kaizen that better encompasses the awesome potential the word carries with it.
  3. Part 3 (8:14)

    What is management and what should leaders be most focused on? Mr. Imai answers this question in this module. Mr. Imai also explains what Detective Columbo has in common with lean thinking managers!
  4. Part 4 (7:02)

    Mr. Imai explains how gemba, or the place the work is done, is like a mirror and why going to gemba is so important
  5. Part 5 (8:41)

    Mr. Imai explains why the gemba was so precious to Sakichi Toyoda and how Kiichiro Toyoda literally grew up at gemba as a child! Mr. Imai also explains the importance of Standard Work.
  6. Part 6 (8:08)

    Mr. Imai explains how lean is a long journey as well as what the Christopher Columbus style of management is all about! Finally, Mr. Imai contrasts traditional companies with lean thinking companies using an analogy you won't soon forget!

Leader Standard Work Course

The concept of Leader Standard Work is not new yet many organizations struggle with it. During this live training seminar—shot at the Peterbilt Manufacturing Facility in Denton, Texas—Mike Wroblewski explains what Leader Standard Work is, how to successfully implement it, and most importantly how to maintain it with the powerful Kamishibai audit system. Please plan approximately 30 minutes of learning time for each module, including watching the video, taking the quiz, and reviewing supporting documents.

  1. Introduction (9:24)

    Mike Wroblewski introduces the concept of Leader Standard Work while managing to draw parallels to successful American football teams.
  2. A Process Focus (11:49)

    Mike challenges the audience with a simple question, "Are you working in the process or on the process?"
  3. Creating Leader Standard Work (15:11)

    Learn the differences between Leader Standard Work for front line supervisors all the way to senior leaders of the company.
  4. Coaching (10:03)

    Watch Mike do a live, and unplanned, Leader Standard Work coaching session.
  5. Visual Controls (9:06)

    Learn the importance of visual controls to successful Leader Standard Work.
  6. The Kamishibai Audit System (14:23)

    Mike explains one of the simplest, yet extremely powerful, auditing systems available today.
  7. Daily Accountability & Discipline (9:32)

    The hardest part of Leader Standard Work is having daily accountability and discipline. Mike explains how to have both in this final video.

Hoshin Planning

Learn how to create a vision, mission, and then a hoshin plan of long-term, breakthrough, and annual objectives. Learn about catchball and the vital process of reflection to create organizational learning.

  1. Hoshin Planning Overview (4:51)

    In this video Ron Pereira introduces the concept of Hoshin Planning, sometimes referred to as Hoshin Kanri or Policy Deployment.
  2. The Mission Statement (3:17)

    Learn how to go about creating a mission statement in this video.
  3. Values and Metrics (5:55)

    Prior to creating a Vision Statement we must reflect on the current state of affairs by examining the company values and metrics.
  4. The Vision (6:21)

    Learn how to create a Vision Statement that inspires and motivates all associates.
  5. Treetop Mission, Values, & Vision (4:28)

    See how Treetop Incorporated, the birdhouse producer we first met in the Transforming your Value Streams course, went about creating their own company Mission, Values, and Vision.
  6. Breakthrough Objectives (6:26)

    Learn what Breakthrough Objectives are and how to create them using tools like the Relations Diagram.
  7. Annual Objectives (10:04)

    Learn how to use the A3 template to set annual objectives and monitor progress.
  8. Catchball (3:09)

    Once objectives are set learn how to deploy them throughout the organization by the catchball process. This isn\'t your typical objective setting process.
  9. Hoshin review (8:39)

    Learn how to monitor the progress of Hoshin initiatives as well as how to use the Countermeasure Report effectively during review meetings.
  10. Problem Solving (5:55)

    In order to succeed at Hoshin Planning all associates must be familiar with the 8 Practical Problem Solving steps. All 8 are explained in this module.
  11. Reflection & Organizational Learning (6:29)

    Learn what yokoten and hansei are and how to leverage both for optimal Hoshin Planning success.

Jean Cunningham on Lean Accounting

Gemba Academy co-founder Kevin Meyer discusses lean accounting with Jean Cunningham. Jean is one of the original thought leaders on the subject.

  1. Introduction (7:30)

    Jean Cunningham describes how she was introduced to lean and lean accounting.
  2. Effect on Owners (7:52)

    Jean Cunningham discusses how lean and lean accounting affects an ownership group.
  3. The Lean Accounting Difference (5:20)

    Jean Cunningham discusses the differences between standard cost accounting and lean accounting.
  4. Implementing Lean Accounting (4:37)

    Jean Cunningham discusses when and how to implement lean accounting.
  5. Resistance to Lean Accounting (7:12)

    Jean Cunningham discusses how to deal with resistance to lean accounting.
  6. Current Projects (3:53)

    Jean Cunningham discusses her current projects with lean accounting and beyond.
  7. Lean Education Advancement Foundation (2:23)

    Jean Cunningham discusses the Lean Education Advancement Foundation, which provides scholarships to educators and students to learn more about lean and lean accounting.

Lean Accounting Course

In this course we're introduced to lean accounting and the problems of traditional cost accounting.

  1. Introduction to Lean Accounting (8:14)

    By the end of this module you’ll understand some of the differences between traditional and lean accounting and why lean accounting is an important part of your organization’s lean journey.
  2. Accounting Basics (7:17)

    By the end of this module you’ll be more familiar with the basic difference between financial and managerial accounting.
  3. Value Stream Costing - Part 1 (8:53)

    By the end of this module you’ll understand the motivation for value stream costing including the steps to design and use a value stream income statement.
  4. Value Stream Costing - Part 2 (8:30)

    Continuing our discussion of Value Stream Costing.
  5. Inventory Management (11:15)

    By the end of this module you’ll understand the problems of using a traditional, standard cost approach to inventory valuation including the impact overproduction can have when traditional cost accounting is performed.
  6. Lean Inventory Valuation (10:24)

    In this module we’d like to share some good news… namely that there’s another, lean friendly, way to perform inventory valuation.
  7. Capacity Management (8:56)

    By the end of this module you’ll know why capacity measures and box scores are important and how to calculate capacity and use capacity measures in decision making.
  8. Product Costs and Decisions (8:52)

    By the end of this module you’ll understand the advantages of using throughput to calculate conversion costs instead of using standard costs; we’ll explain how features and characteristic costing can help with pricing decisions, and we’ll show a better way to evaluate product mix, special orders, and make vs. buy decisions.
  9. Target Costing (7:19)

    By the end of this module you’ll understand the difference between cost plus and target costing. We’ll also discuss how to evaluate customer value when designing new products or improving existing products.
  10. Performance Measures (6:38)

    By the end of this module you’ll know why measures should change once lean accounting is adopted and the resistance organizations sometimes face when they attempt to make these changes.
  11. One Day Close (8:44)

    By the end of this module you’ll understand a simple way to calculate the costs of closing the books… we’ll also provide some tips to help reduce the time-to-close, and, in the process, we’ll discuss the important difference between being accurate and being precise while preparing the books.
  12. Lean Accounting Resources (3:21)

    By the end of this module you’ll know which lean accounting books, networks, and conferences we recommend.

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