Lean Specialist Course Outline

Module 1: Advanced Certificate in Strategic Lean Management
(6-hour)

1.1 Lean Vision
1.2 Identify Improvement Opportunities
1.3 The Latest Strategy of Lean Improvement
1.4 Case Study
1.5 Why Lean + TOC
1.6 Case Example
1.7 Strategies to World-class Organization
1.8 Comparison of Different Approaches
1.9 Video Show
1.10 Managerial Decision Making for Lean Leaders

 

Module 2: Advanced Certificate in Lean Transformation
(9-hour)

2.1 Introduction
2.2 Lean Transformation Process
2.3 Value Stream maps
2.4 Case Study
2.5 Evaluate the current situation
2.6 Identify areas of opportunity
2.7 Modify the existing process
2.8 Implement new Standard Work
2.9 Case Examples
2.10 Video Show

 

Module 3: Advanced Certificate in Flow Management and Kanban System
(6-hour)

3.1 Concept of Flow Management
3.2 Ground Work and Preparation
3.3 One-piece Flow
3.4 Make Equipment Compact
3.5 Create U-shaped Manufacturing Cells
3.6 Video Show
3.7 Multi-process Operations
3.8 Training Multi-Process Workers
3.9 Synchronization
3.10 Case Study An Automotive Electrical Parts Factory
3.11 The Kanban System
3.12 Balance the Flow VS Balance the Load

 

Module 4: Advanced Certificate in Elimination and Capacity Exploitation
(6-hour)

4.1 Why Wastes Occur?
4.2 7 Types of Wastes
4.3 How to Identify Wastes
4.4 How to Eliminate Wastes
4.5 Secrets for Not to Creating Wastes
4.6 Case Examples
4.7 5S’s and Its Deployment
4.8 Capacity Exploitation
4.9 Increase Capacity by Reducing Variations
4.10 Increase Profit by Rationalize Product Portfolio

 

Module 5: Advanced Certificate in Leveling Techniques and Balance Flow Scheduling
(6-hour)

5.1 What is Level Production or Level Service
5.2 Lean Scheduling
5.3 Leveling Techniques
5.4 Balanced Flow Scheduling
5.5 Procedures for Changeover Improvement
5.6 Video Show
5.7 The Poke-Yoke System
5.8 Video Show
5.9 The Audit List
5.10 Examples

 

Module 6: Advanced Certificate in Operations Improvement Techniques
(6-hour)

6.1 Overview of Standard Operations
6.2 How to Establish Standard Operations
6.3 Case Study
6.4 How to Improve Operations
6.5 Steps toward Jidoka
6.6 Total Productive Maintenance, TPM
6.7 Strategies for Zero Injury and Zero Accidents
6.8 Examples
6.9 A New Way for Production Management – Managing Time Buffer
6.10 A Case Study of Transfer Batch

 

Module 7: Lean Study Visit

  • Optional, all detail to be advised

 

Examination

  • Participants should attend the examination after completed Module 1- 6

 

VIVA Exam

  • 30-minute individual project presentation + 30-minute Q & A session