CANCELED FOR JANUARY 2014. Please check back for future dates.
Cost: $1,995 per person / $1,795 for Made in Washington members (includes all course materials, books and certificate exam)
Information: Linda Adams – (425) 438-1146 x107
Impact Washington’s Lean Enterprise Certificate Program trains participants on the elements of the Lean Enterprise that, when implemented, can transform a company. Manufacturers that implement Lean experience dramatic improvements in the areas of productivity, space, quality and lead-time.
Over seven days (one day a week every other week), students will participate in a combination of training and practical application in preparation for the nationally-recognized Lean Certificate examination. The examination will be given on the last day of the class.
The program begins with the Principles of Lean Manufacturing with Live Simulation (Lean 101). This introductory seminar combines classroom discussion and live simulation to demonstrate the principles of Lean Manufacturing. Lean 101, or equivalent, or basic Lean knowledge, is a prerequisite for the remaining course in the program.
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. During this portion, students learn the common language of Lean as they draw the 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; visual devices are powerful solutions for working smarter, not harder. Organization and orderliness are 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 (during this class the students will identify a lean project they wish to work on to complete their practicum requirement).
Day 3: Set-Up Reduction/Quick Changeover, Pull/Kan Ban 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 thus reducing 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: Problem Solving, Process Design, Quality, Productivity & Delivery Measures Product Development and Leadership & High Performing Teams. 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 are covered 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 5: Plant visits will be arranged to visit local plants that are successfully implementing Lean Manufacturing Processes.
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. On day six, student teams will present their project to their classmates.
Day 7: SME Exam. The class will spend the day reviewing in preparation for a 150 question multiple choice test to be given.
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.