Lean Certification

Lean 101- Principles of Lean Manufacturing
Combined classroom and hands-on simulation of an operating factory in a 1-day, 8-hour course. This is the first step in learning the principles of Lean manufacturing. No previous experience is required. The course is a mix of classroom and live simulation. You begin by manufacturing simulated circuit boards in a traditional forecasted manufacturing setting. The results of the simulation provide the basis for continuous improvement by applying Lean manufacturing principles. Performance improvements are measured and compared for improved results.

5S Workspace Organization
5S is one of many important tools used within the Lean method to help create and maintain order. You will learn how to assess an area and apply a systematic approach to create order and efficiency within a workspace. You will explore systems to help maintain improvements over the long term. These principles will be applied in an out-of-class, hands-on project.

Standardized Work
In this eight hour class you will explore standard work as an element of continuous improvement, identify the steps in creating and maintaining standards, identify the processes for improving standards, examine the key formulas, tables and worksheets to create standard work and determine the applications of standard work for training, improvements, and decision making. Class is part of Level 1 of the Lean Practitioner Certificate.

Leading Lean Transformation
Learn to lead and manage the culture change. Translate vision into reality. Prioritize actions through policy deployment. Learn to introduce new products smoothly and in less time. 

Kaizen-Rapid Improvement
Learn the philosophy of continuous improvement and the elements of rapid improvement through making workplace changes, selecting and using cross functional teams, conducting successful Kaizen events, and creating an effective support structure.

Process Mapping
Participants are introduced to process mapping and value stream maps. You will learn how to create a process map, the common language and icons associated with maps, and how to use the maps to create a plan for the future. These principles will be applied in a hands-on project.

Value Stream Mapping
Value stream mapping creates a visual representation of all product and information flows from raw material receiving to shipping finished products. By including all value added and non-value added (waste) activities in the value stream needed to produce a product, improvement opportunities are identified along with the logical sequence for implementing them. Then a future-state map is drawn to create the blueprint for Lean transformation. Applying VSM to a high-priority pilot process allows companies to demonstrate results that will assure continued interest in applying Lean concepts.

Introduction to A3 Problem Solving
Learn the power of A3 reporting to address the root causes of problems every day at work. This introductory course prepares you to contribute to the A3 process, dramatically increasing the probability of success. Leading companies, such as Toyota, use this proven and structured problem-solving approach.

Cellular Flow
This hands-on course teaches how to link and balance manufacturing operations to reduce lead times, minimize work-in-process, optimize floor space usage, and improve productivity through a combined classroom and hands-on simulation. The instructor leads the class through the 5-step process for designing and implementing cellular flow.

Pull/Kanban
Students will learn how to control shop floor inventory and production schedules by implementing pull systems. This course teaches how to design and implement a visually-driven, employee-controlled, material replenishment system. Participants also learn how to implement repetitive and non-repetitive pull systems, set up point-of-use material storage, interface with planning systems, and balance lot sizes with capacity. Prerequisites: Lean 101 and Lean Mapping Tools. Participants should be proficient with fractions and ratios, data tables and able to solve equations.

Setup Reduction
This course teaches the fundamental principles of setup reduction. The instructor will clearly define setup and discuss reasons and barriers to reducing setup time. The course follows the principles first expressed by Dr. Shigeo Shingo and his work in Single Minute Exchange of Dies (SMED). Participants learn the standard methodology in applying SMED to any type of setup in industry.

Total Productive Maintenance
This course offers the student a method to proactively maintain machines and equipment at their peak productivity. Participants come away with an understanding of TPM and its five major components. Each student will understand how TPM increases overall equipment effectiveness and how it can help avoid interruptions to production. The course provides a deep understanding of the seven steps to process maintenance.

Performance Measurement
Learn various performance measurement systems, from the basic to the complex. You will consider a wide variety of measurement needs, from the shop floor to top management reviews. Find out what works to get measured results.