Lean Specialist Certification Programme Course Outline

Curriculum

1. Strategic Considerations

   Learn how to integrate Lean practices with the overall strategy of the firm. This module will focus on identifying how Lean manufacturing contributes to building value for the customer.

2. Planning and Implementing Lean

   This module will detail the need for enterprise-wide waste elimination and demonstrate a systemic approach to get everyone in the enterprise involved in the process. Participants will learn how to align corporate objectives/initiatives with workplace activities and day-to-day operations. The implementation roadmaps will be explored.

3. Value Stream Management

   The Lean journey starts by presenting the step-by-step methodology of value stream management. Value stream management is the stepping stone to planning the implementation of all Lean activities. Learn value stream mapping and story-boarding. Learn how to gather all the upstream and downstream information needed to make data-driven decisions regarding your Lean plan and the subsequent elimination of all non-value adding activities.

4. 5S and Visual Workplace

   Learn the principles and techniques to apply 5S and establish visual management systems to improve workplace communication. You will learn how to share information and establish standard work: we’ll deal with problems, abnormalities, waste, and unsafe conditions through visual display and controls, so that everyone understands at a glance what is going on in the workplace.

5. Mistake Proofing

   The best way to prevent defects is to examine the process, determine what condition led to the defect, and then control that condition. Mistake-Proofing (poka-yoke) devices automatically inspect for errors or defective operating conditions. This module will teach you a scientific method to alert, avoid, and control defects and eliminate source errors.

6. Quick Changeover

   Learn the methodology that minimizes the time wasted during changeovers and setups. This module will teach you to minimize waste found in the changeover process. Learn the difference between internal and external elements of work, how to streamline internal and external activities and how to significantly reduce changeover times at minimal cost.

7. Lean Equipment Management

   In this module explains the importance of improving equipment effectiveness and extending useful equipment life in the context of a Lean enterprise. The significance of Overall Equipment Effectiveness (OEE) will be addressed.

8. Kanban and Pull Production—Leveling

   This module offers a deep dive into Kanban and flow production. Understand the methodology of Kanban and how it can stabilize production operations. Explore the ways Kanban can prevent expensive product shortages; how and where it fits in a Lean value stream; and how it interrelates and integrates with other Lean tools.

9. Cell Design and One Piece Flow

   Cellular manufacturing can boost a company’s competitiveness by eliminating wasted motion, space and inventory from the production process. This module will demonstrate how to create cells for one-piece-flow by exploring takt time, jidoka, and the necessary tools of standard work such as standard work sheets, process capacity tables, and standard work combination sheets.

10. Lean Logistic/Supply Chain

    Learn about the new methodologies for a Lean supply chain. A system where inventory, transportation, warehousing, demand information, and sourcing and procurement both up and down the supply chain are integrated. The discussions will be focused on the coordination and collaboration with channel partners: suppliers, intermediaries, third party service providers, and customers.

11. Project Management

    Project management is central to continuous improvement. In this module we’ll explore project management principles, success factors, management guidelines, the easy to use practices of monitoring project status, and the aggregate contribution to the company’s improvement strategy and initiatives.

12. Program Recap and Exam Preparation