Lean Practitioner Certification

Would you like to experience the benefits of Lean manufacturing? For many, the first step in creating a culture of continuous improvement and developing an army of problem solvers is to help all employees identify opportunities for improvement. Participants gain knowledge and the tools required in order to help a critical mass of employees learn how to define value and identify and eliminate waste. After completing the workshop, participants will have experienced the difference between traditional and Lean manufacturing and its components.

Tools and Topics Learned Include:

• The common forms of waste
• Practical brainstorming techniques
• Kanban
• Visual Controls
• Kaizen Events
• Teamwork
• Value Stream Mapping
• Cellular manufacturing
• Work Standardization

Mapping demonstrates how Lean thinking can reduce process timelines and improve quality and delivery to schedule. In this session, participants will map out real processes and learn about pre and post mapping tools to add to their personal toolbox. Participants will learn a simple 3-step process for change management and leave with an entire cache of tools to assist through successful process improvement deployment and sustainment.

Tools and Topics Learned Include:

• Lean Principles for Mapping
• Prework for Successful Mapping Sessions
• Swim Lane Mapping, Value Stream, Spaghetti, Ideal State, and Future State Maps
• Post Mapping Tools
• The People Side of Change Management-3 Step Process

Does the desire to act overpower the need to understand? Understanding the problem, the process, the people and the distinctions between the types of causes are all stepping stones to effective root cause analysis to permanently eliminate problems from recurring. When structured methods and tools are used, this can be accomplished.

Tools and Topics Learned Include:

• RCA Principles and Process Steps
• Importance of Group Dynamics and having the RIGHT team
• Tools to assist in thoroughly defining the Problem Statement
• RCA tools for identifying symptoms, contributing causes and root causes
• Why the 5 Why Technique isn’t always enough
• Importance of performing data collection and validation

Customers, employees and suppliers can tell a well-run plant and office without a narrated tour. The visual clues are everywhere. This is a straightforward approach that impacts your customer and employee image, productivity and sales. The many facets of visual management and 5S can allow employees to show pride and organization in their area, give them performance feedback, provide incentive to hit their goals, illustrate what is expected of them and recognize a job well done. These techniques can help overcome language and reading barriers and boost learning retention too.

Tools and Topics Learned Include:

• Visual display boards
• Standard work boards
• Visual control boards
• Color-coding time savers
• Motivating teams for higher performance
• Pictorial procedures
• Visual performance measurements
• 5S organizing and housekeeping

“Without Standard Work, there can be no improvement.” This statement is a central truth of the Toyota Production System. Standard work defines the current best work process. It is the baseline for continuous improvement and is a tool used in auditing processes. Therefore, conformance to standard work contributes to the results you need to stay competitive but is something we really don’t want to do. Until you can apply repeatable standard work successfully, improvements will yield less than their full potential and backsliding will be prevalent. Participants will walk away with the knowledge, tools, and confidence they need to be able to begin to apply Standard Work in their operations on the very next day.

Tools and Topics Learned Include:

• Time and motion study techniques
• Work cell and assembly line loading
• Details of standardized work documents
• Developing a process to sustain standardized work

Do you need productivity and cost improvements now? This workshop will provide the education and experience that is necessary for you to deploy rapid improvement teams at work. Participants will learn to measure what is important, gather the necessary resources, decide who does what, and set and accomplish a one week schedule for project completion. Most importantly, you will see how to accomplish more in less time than most teams take to agree on what they should be doing. Attendees participate in interactive team exercises that demonstrate in a practical manner the application of rapid improvement principles and techniques.

Tools and Topics Learned Include:

• Rapid improvement process tools
• Performance measurement tools
• Simulation of a rapid improvement project
• How to overcome barriers

Certification Project: All certification applicants are required to demonstrate their ability to apply what they learn by completing a project. This project must include measurable results that benefit the company.

Certification Tests: All certification applicants are required to complete a test after each workshop. Each test is approximately 15 multiple choice questions and intended to help everyone speak the same language. Tests are open book and can be taken multiple times.

Certification Coaching: All certification applicants are required to complete a Learning to Solve Problems coaching session. During coaching you will learn how to be successful from project set-up to completion, recognize and mitigate bias, objectively define problems, learn where, how and when to access resources, and apply the Project Template as a project management tool.