Syllabus
Description of Course
The A3 Problem Solving (LT-M4) master’s course is a continuation of the content learned in the Lean Thinking Advanced Course (LT-A1). This course is based on the A3 technique used in Toyota known as Toyota Business Practices (TBP). It is also known in Europe as Practical Problem Solving (PPS).
The A3 Problem Solving approach is infamous within Lean Thinking, having been developed in Toyota as TBP. This course teaches you the same approach and aspects of A3 Problem Solving that Toyota uses. It will ensure that you know the differences between Point of Cause Analysis and Root Cause Analysis, something that is often overlooked in similar courses.
You will learn how to create an A3 problem solving paper, how to define the problem, measure the discrepancy from standard or gap if no standard exists, breakdown the problem, identify points of the cause, set a target condition, do root cause analysis, define countermeasures to the problem and assess them effectively and then implement them.
In addition, you will be able to effectively evaluate results and processes, understand the importance of standardizing improvements, and determine why Yokoten is important. You will also learn that the final step in an A3 Problem Solving paper is kaizen.
You will also learn why TBP comes after Ji Kotei Kanketsu (LT-M3), also known simply as JKK, and how the two approaches work together to establish exceptional quality and operational excellence.
Duration of Training
The A3 Problem Solving (LT-M4) master’s course requires 16 hours of training and can be taken as a two-day in-person training session, an online live virtual class, or as an asynchronous self-paced online training using The Flow System’s learning management system (LMS). This course can be taught publicly or privately to any organization.
Participants must complete the training before receiving a code allowing them to take the A3 Problem Solving (LT-M4) assessment for accreditation. The fee for the assessment is included in the course fee for training attendees.
At the master’s level, participants will demonstrate an ability to apply the new knowledge and complete an online assessment. The master’s level courses’ application portion will be reviewed by peers and industry experts in their chosen field.
Participants who attend the training will have two attempts at the A3 Problem Solving (LT-M4) assessment. Participants who wish to forgo the training and jump straight to the assessment may do so but must first buy a code and will only have one attempt as opposed to two for people taking the training. You can buy a code below by clicking ‘Take Assessment.’
Objectives of Course
This course is a master’s course that continues to build on the material learned from both the Foundations (FS-1) and the Lean Thinking Advanced (LT-A1) courses. As a mastery level course, participants will be required to envision applying the material covered in the course to their place of work. After successfully completing this course participants should be able to:
- Explain the A3 Problem Solving process.
- Create an A3 Problem Solving A3 paper.
- Exhibit the ability to conduct a Point of Cause Analysis.
- Exhibit the ability to conduct a Root Cause Analysis.
- Describe effective nemawashi.
- Apply the technique learned to their own problems.
- Exhibit an ability to integrate the above approaches into operational excellence processes.
- Define and create a standardized work process.
- Evaluate A3 papers for effectiveness and correctness.