• Lean Manufacturing

Lean Manufacturing 10-Day Certification Program Components

All ten-day (80 hours) programs begin with a one-day Overview of Lean Manufacturing, covering the history, philosophy, and core methodologies of Lean Manufacturing. The remainder of the program is comprised of three core categories: Lean System Design, Supporting Lean Tools and Methods, and Leadership and Team Management Tools and Methods. Each of these categories has several modules that fit within each category.

 

Lean System Design

3+ modules required for 10-day certificate program

Value Stream Mapping
  • Current state mapping
  • Future state mapping
  • Design of Pull
Design of Pull Systems
  • Kanban quantities
  • Container sizes
  • Analytical tools to determine inventory
Factory Layout for Lean Manufacturing
  • Basic models
  • Practical solution methods
The Physics of Lean: Using Science to Evaluate and Improve Manufacturing Systems (2 Days)
  • Identify leverage points with greatest impact on the bottom line
  • Throughput
  • Cycle times
  • Customer service
  • Quality
  • Flexibility
Build to Order
  • Supplier involvement
  • Material control systems
  • Logistic systems design
  • Manufacturing-supplier partnerships
 
 

Supporting Lean Tools and Methods

2+ modules required for 10-day certificate program

Cell Analysis and Design: Creating Continuous Flow
  • Grouping products in cells
  • Cell layout Allocating work
  • Right-sizing equipment for cells
Implementing Kaizen Bursts
  • Creating systems around each tool
  • Translating value stream maps into action plans
  • Building JIT and Built-in-Quality pillar tool systems
Learning to Levelize through Pull Systems
  • Mechanics of pull systems
  • Kanban quantities
  • Container size
  • Alternative methods
  • Simulation
Material Handling for Lean
  • Evaluate impact of parameters
  • Learn the use of analytical modeling to design call systems
  • Practice the method as both student and teacher
Building/Developing Work Groups & Standard Work (cross-listed under Leadership and Team Management Tools and Methods)
  • Methodology for developing standardized work
  • Tips on how to lead people to follow the standards
  • Ensure quick, accurate and complete training of team members
  • Break down jobs into elemental components for easy comprehension
  • Fostering team work
  • Motivating teams to identify and solve problems
  • Developing team structure
Lean Rapid Plant Assessment
  • Learn to quickly assess the state of a plant or operation
  • Use the quick assessment to develop realistic improvement plans
  • Determine your operation's value
 

Leadership and Team Management Tools and Methods

2+ modules required for 10-day certificate program

Integrating Six Sigma in Lean Systems
  • How lean and six sigma work together
  • Every employee as a problem-solver
  • Review of DMAIC (Define, Measure, Analyze, Improve, and Control)
Leading the Change to Lean
  • Optimizing the total system
  • Tools and methods for leading change
Accounting and Measurement for Lean Manufacturing
  • Using alternative accounting and measurement systems
  • Encouraging appropriate behavior in lean systems
Building/Developing Work Groups & Standard Work (cross-listed under Supporting Lean Tools and Methods)
  • Methodology for developing standardized work
  • Tips on how to lead people to follow the standards
  • Ensure quick, accurate and complete training of team members
  • Break down jobs into elemental components for easy comprehension
  • Fostering team work
  • Motivating teams to identify and solve problems
  • Developing team structure