Lean Certification Online

Level 3 – Lean Expert

The “10 Steps to become a Lean Enterprise” program culminates with the Level 3 – Lean Expert series of training modules. Level 3 integrates the foundational knowledge from Level 1 - Lean Awareness and the application procedures in the Level 2 – Lean Practitioner training modules.

Level 3 - Lean Expert allows the learner to develop an advanced level of knowledge about the implementation and integration of Lean Principles into every level of an organization. The learner is taken through a systematic process using the “10 Steps to become a Lean Enterprise” model to help focus and prioritize all the implementation and integration activities.

As a learner completes each level of the Lean Certification Online training modules, they will increase their personal knowledge and develop the ability to apply the “10 Steps to become a Lean Enterprise” model into any business environment.

Course Outline:

Part 1 - Introduction to Level 3 – Lean Expert

• Overview of the 10 Steps training program.
• Establishing a Lean Enterprise culture.
• Understanding people and their actions.
• Transformational thinking in a Lean Enterprise. /li>
• Systemic integration of the:
• LEAN model
• ISEE cycle.
• 3 key components
• 5 cultural enablers.

Part 2 - Step 1: Strategy Deployment

• Strategy Deployment application process.
• Identifying strategic focus areas.
• Defining key strategic initiatives in each focus area.
• Defining key performance metrics (KPM’S) for each strategic initiative.
• Defining roles and responsibilities for strategic initiatives.
• Developing a Strategy Deployment implementation plan.
• Execution and evaluation of strategic initiatives.

Part 3 - Step 2: Value Stream Mapping

• Evaluate strategic initiatives using value stream mapping.
• Developing a data collection plan.
• Identifying product groups.
• Developing a current state value stream map.
• Identifying opportunities for improvement
• Developing a future state stream map.
• Develop a value stream implementation plan

Part 4 - Step 3: Workplace Organization Overview

• Establishing a robust 5S system.
• Establishing a Visual Workplace.
• Sustaining a Visual Workplace.

Part 5 - Step 4: Improve Product Flow

• Understanding how flow affects a value stream?
• Understanding the keys to establishing and improving product flow.
• Understanding the importance of workplace ergonomics
• Understanding how workplace design can help to improve flow.

Part 6 - Step 5: Quick Changeovers

• Using QC to improve production flexibility.
• SMED
• OTED
• OEE

Part 7- Step 6: Implement a Pull System

• Establishing “kanban”?
• Coordinating inventory and work in process.
• Aligning the value stream using takt.

Part 8 - Step 7: Balance the Workload

• Balancing workstation cycle times.
• Balancing production scheduling.
• Balancing single vs. mixed model production.

Part 9 - Step 8: Develop Standardized Work

• Developing standardized work.
• Purpose of standardized work documents.
• Applying standardized work.
• Sustaining standardized work.

Part 10 - Step 9: Continuous Process Improvement (CPI)

• Facilitating Rapid Improvement Events (RIE).
• Using problem solving techniques to identify and eliminate waste.
• Overview of Total Productive Maintenance (TPM).
• Achieving Zero Defects.
• Overview of Lean Six Sigma

Part 11 - Step 10: Extend your Lean efforts into the Supply Chain

• Supply Chain Logistics.
• Interpreting your customer’s needs.
• Interpreting your supplier’s needs.
• Establishing collaborative Supplier/Customer relationships.