Coming Winter 2014-2015
Cost: $1,995 per person / $1,795 for Made in Washington members (includes all course materials, books and certificate exam)
Information for Spokane: Patric Sazama – (509) 343-3170 or Mike Schneider – (509) 981-6348
Your Opportunity to Develop Internal Lean Champions
Companies that realize sustained success with Lean implementation know that developing their employees’ capabilities to lead continuous improvement efforts is key to their success. The Lean Enterprise Certificate Program arms participants with demonstrated understanding of the Lean body of knowledge and provides them hands-on practice applying Lean tools and strategies.
Benefits to an Organization
- Development of internal Lean champions
- Enables employee involvement in sustained continuous improvement
- Helps an organization build a Lean transformation
- With a curriculum comprised of both classroom and project application, the program provides seven days of Lean training to individuals who can then play roles as Lean Champions in their organizations. Participants earn a certificate of completion.
- A three-hour exam from the Society of Manufacturing Engineers based on the instructional material and the required texts is administered at the end of the program, through which participants demonstrate understanding of the Lean Body of Knowledge. This certified test completion, along with additional project hours, can be applied towards a Bronze Level Certification and career progression for silver and gold certification (listed at www.sme.org).
- The training will be combined with tours of local companies employing best practices in order to demonstrate and visualize Lean techniques in practice.
Each Lean Enterprise Certificate Program (LECP) participant will:
- Have demonstrated knowledge of the Lean Body of Knowledge
- Apply their learning to their organization with a practicum project
- Go back to their organization equipped to help champion continuous improvement
Certificate Program Curriculum
Day 1: Introduction to Lean Manufacturing. This will consist of an introductory seminar that will combine the theory of Lean Manufacturing with a live simulation that incorporates the theory learned in the presentation.
Day 2: Introduction to the Theory of Value Stream Mapping, Workplace Organization and Standardization, 5-S and Cellular Flow. Students learn the common language of Lean as they draw a current state map for a company, analyze that current state, find the non-value added activities and draw a future state map that eliminates those unnecessary activities. This section looks at the visual factory, with organization and orderliness stressed. Cellular flow is the linking of manual and machine operations into the most efficient combination of resources to maximize value-added content while minimizing waste.
Day 3: Set-Up Reduction/Quick Changeover, Pull/Kanban and Total Production Maintenance. Set-Up reduction teaches a systematic, low cost, shop-proven method that has reduced set up and turnaround time in all types of manufacturing environments. In addition, this class will cover the effectiveness of Pull Kanban systems to drive velocity to reduce the costs of over production. Pull Systems and Kanbans control the flow of resources in a production process by replacing only what has been consumed. Total Productive Maintenance will also be presented to the student. TPM is a strategy to maximize the productivity of equipment over its entire life while reducing downtime, improving quality and increasing capacity while minimizing capital expenditures.
Day 4 and 5: Problem Solving, Process Design, Quality, Productivity & Delivery Measures Product Development and Leadership & High Performing Teams. The Daily Improvement Kata. Models of problem solving approaches including the Deming cycle and Six Sigma’s DMAIC are reviewed. Gap Analysis, Brainstorming, 5 Why’s, and root cause analysis are covered. In addition, Flow Charting, Pareto Charts, Histograms and Cause Effect Diagrams are presented. This training also includes the value of Vision, Mission and Values to an organization. Policy deployment and the roles and responsibilities of employees and leaders are discussed. Leading change in a continuous improvement culture is presented. Designing and improving process strategies iscovered in this section. Variety Reduction, Engineering Changes and Design for Manufacture and Design for Assembly are key components of Product Design and Development that are presented.
Day 6: Practicum. In addition to the presentation of the Theory of Lean, students will be assigned to work with a team on a practical application of a key component of a Lean Transformation. Students will present their projects.
Day 7: Society of Manufacturing Engineers Lean Bronze Exam. Company Tours and Exam Preparation are interspersed among the days of instruction outlined above.
Books provided as part of the registration fee are: Lean Thinking by James Womack and Daniel Jones, Gemba Kaizen by Masaaki Imai, Lean Production Simplified by Pascal Dennis and Learning to See by Mike Rother and John Shook. In addition, instructional manuals that reflect the classroom presentations will be provided.