Lean Manager Certificate 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.

Homework Report-outs

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.

5S and The 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.

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.

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.

Lean Equipment Management

In this module we will explain the importance of improving equipment effectiveness and extending useful equipment life in the context of a lean enterprise. Lean equipment management (LEM) focuses on the equipment and process constraints surfaced by your value stream maps. In this implementation process, LEM establishes and ensures adherence to standardized equipment conditions and maintenance practices necessary for lean production. We'll discuss both basic and advanced techniques including early equipment management, maintenance process improvement, and autonomous maintenance and how they link together to create a lean equipment management system. Achieving equipment reliability and capability is the central theme. In this module we'll also review the significance of Overall Equipment Effectiveness (OEE).

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.

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.