Lean Manager Certification Program

Week 2 Curriculum

The first activity of this week is to present the outcome of what was learned during the application of the homework from the intervening weeks, for review and information sharing among the participants. Now that the data has been gathered and each project's scope has been verified, the learning this week will be centered on methods used early in the implementation of a Lean environment-those that are most often piloted in the plant as an initial effort. Although these techniques will later be transferred tolarge segments of the organization during the deployment phase, they are often started by small groups in areas that are identified in the value stream map from the previous week's activity.

The module on manufacturing measurables is taught here as well so that the metrics scheme can track improvements as soon as they are generated. Upon completion of week 2, the participants are again returned to their specific project area with the express assignment to pilot the project area and return with the measured results.

The individual projects selected by the participants will be reviewed during this session for appropriateness and business value. The business benefit from all the LMAC curriculum will depend directly on the scope of the individual improvement project. (If necessary, the predetermined project can be changed based on the outcome of the first week's session.)

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Homework Reports

For weeks 2, 3, and 4, each training week will begin with a report-out session. Each participant will be required to prepare and make a brief presentation explaining the learning and discoveries made by completing each homework assignment. The focus on the report out is solely on sharing learning, not presentation skills. These report-out sessions offer great opportunities to address real world lean implementation issues, so questions and "yea buts" are strongly encouraged.

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Visual Workplace

Learn the principles and techniques to apply 5S and establish visual management systems to improve workplace communication and adherence to standards. This module will teach you how to share information and establish standard work: we'll deal with problems, abnormalities, waste, and unsafe conditions through visual display and controls and procedures, so that everyone understands at a glance what is going on in the workplace.

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Standard Work

In both manufacturing and service operations, standard work is a key element in the elimination of waste and excess inventory and in achieving balanced and synchronized delivery processes. In this session, participants will learn a proven methodology to develop a standard procedure, and then apply document control and visual workplace principles and techniques to train others in their new best practice, or standard work.

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Quick Changeover

Learn the methodology that minimizes the time wasted during changeovers and setups. This module will teach you to minimize waste found in the production process and begin the road to a lean production system. Learn the difference between internal and external elements of work, how to streamline internal and external activities and how to significantly reduce changeover times at minimal cost. We'll explore applying the methodology throughout the enterprise.

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Mistake Proofing

The best way to prevent defects is to examine the process, determine what condition led to the defect, and then control that condition. Mistake-Proofing (poka-yoke) devices automatically inspect for errors or defective operating conditions. This module will demonstrate a scientific method to alert, avoid, and control defects and eliminate source errors.

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Total Productive Maintenance

In this module we will explore an array of principals and methodologies essential to equipment reliability and the lowering of equipment life cycle cost in the context of a lean enterprise. During the session, we will review each of the eight TPM Pillars, how they relate to each other and how they link together to support an overall lean management system. We'll discuss both basic and advanced practices, how these practices are applied in a variety of industries, and we will review the significance of Overall Equipment Effectiveness (OEE).

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Plant Application

Participants will travel to a local manufacturing facility for a hands-on application. while at the facility, participants will be assigned specific project areas where they will work as a team to execute a variety of Lean applications taken from the classroom learning. Teams will apply the various process improvement tools, make recommendations for improvement,and report on their findings.

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Project Roundtable

This is an opportunity for the participants to share in their individual lean journey issues, obstacles, and barriers to the implementation process. A joint-sharing of lean perspectives and leveraging of the groups first-hand learning and knowledge to assist with countermeasures and suggested course corrections. What works and how to leverage the experience throughout the enterprise.

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Homework

At the conclusion of each weeks training session, several homework assignments will be made. These assignments are structured to further reinforce the learning that takes place in the classroom sessions.

Homework assignments will include items such as gathering and analyzing information to facilitate planning for your transformation process, selecting an initial application (pilot) area, completing your current state value stream map, designing manufacturing cells, and implementing Kanban pull systems. At the time homework assignments are made, detailed requirement information will be communicated to each participant.

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Lean Manager Certification Program Curriculum

Week 1: Plan Week 2: Pilot Week 3: Deploy Week 4: Integrate