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Basic Lean Sigma Principles
Lean Certificate Program Outline

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1.Lean Business Simulation© Course Outline

Overview: The Lean Business Simulation© course is an interactive workshop where participants learn the reason for change, the methods of change and the tools and techniques of change. They actually run a business which requires them to identify the issues and select the appropriate SCM/Lean/Six Sigma tools or techniques to apply and see the results of their efforts. The session is renowned for its ability to get to the “AHA” as well as energize and motivate participants to action.

Key Learning Points:
-Value Stream Mapping
-Visual Factory Management
-Change Management
-Cycle-Time Reduction
-DMAIC: Six Sigma methodology
-5S
-Kaizen
-Kanban
-One-Piece Flow
-Vender Managed Inventory
-Error-Proofing / Poka-Yoke
-Problem-Solving Techniques
-Process Improvement
-Standardization
-Supplier Certification
-Structured Management System
-Teamwork

Deliverables:
-Classroom training
-Basic understanding of Lean Enterprise and Six Sigma methodologies
-Presentation documents and workshop session results

Administration:
-Team participant size will be 12-25 employees.
-Attendees will include management, operators, engineers, and supervisors.

2.5S Classroom and Practical Training Course Outline

Overview: This course will provide the participants with a thorough understanding of the tools and techniques for delivering a world class 5S program. Additionally, students will gain insights into the practical application of the cultural aspects associated with this fundamental tool of lean while demonstrating their learning through actual training based implementation.

Key Learning Points:
-Red Tag Strategy
-Performance Boards

Deliverables:
-Classroom training
-Field training and application
-Training material
-Pictures of before and after sessions
-Implemented Pilot 5S program (2 areas TBD)
-Visible Measurement system

Administration:
Attendees will include floor staff, engineers, and supervisors.

3.Visual Factory Management Course Outline

Overview: To measure and control processes to maximize throughput and optimize capacity utilization, while providing immediate feedback to the point of production. Particpants will learn to develop goals and objectives, implement performance measurement processes and provide an internal‘system for managing’ goal deployment across the organization.

Key Learning Points:
-Goal Roll-down
-Execution/visual control systems
-Barrier removal process
-KPI development (pilot)
-Feedback loops
-Reward and recognition system
-CPI Teams

Deliverables:
-Classroom training
-Training documents

Administration:
-Attendees will include floor staff, professional staff and supervision.

4.Engineering Design and Group Technology Training Course Outline

Overview: This course will provide the participants with a methodology for product development which incorporates Design For Manufacturing/ Assembly, Concurrent Engineering, Value Analysis/Value Engineering, and Standardization. Students will learn how to establish an environment to coordinate product and assembly process development.

Key Learning Points:
-Design For Manufacturing/Assembly
-Value Analysis/Value Engineering
-Group Technology
-Concurrent Engineering

Deliverables:
-Classroom training
-Training documents

Administration:
-Attendees will include floor staff, professional staff and supervision.

5.Value Stream Mapping- Macro Process Flow Course Outline

Overview: This course will provide the participants with a methodology value sream mapping key internal processes. Concepts of value-added analysis, cycle-time anlaysis and data analysis will be explored through developing current state process value maps.

Key Learning Points:
-Value Stream Training Workshop
-Value stream map current process
-Perform VA / NVA analysis of current process
-Lead the team through a formalized process to identify key areas of opportunities for improvement and benefits.

Deliverables:
-Value Stream Mapping workshop
-Value stream map of current process – macro level only
-Customer Order through Order Delivery
-Identification of key areas for improvement opportunities
-Identification of process owner

Administration:
Attendees will include floor staff, engineering and supervision

6.Flow Manufacturing Training Course Outline

Overview: Attendees will learn how flow manufacturing is a reliable method for designing flexible production flows utilizing a blend of Lean Manufacturing, Just-In-Time, Takt-time, Level-Scheduling, Kanban Replenishment, One-Piece Flow and Kaizen methods

Key Learning Points:
-As-Is Analysis and To-Be Redesign
-Takt Time
-Cycle Time
-Value Add and Non-value Add Identification
-Error-Proofing
-Layout design
-Kaizen methodology
-Flow design
-Resource Integration

Deliverables:
Classroom training
Training documents
Pilot Program ( 2 areas TBD)

Administration:
Attendees will include floor staff, engineering and supervision

7.Supply Chain Development Training Course Outline

Overview: This course will provide students methodologies on how to identifay and develop strategic suppliers, certifiy them and identify total cost of ownership of procured items and services. Students wills also learn data analysis, inventory profiling and the ability to indentify the root causes of inventory growth, skrinkage, loss and waste.

Key Learning Points:
-Replenishment models
-Value Engineering
-Supplier Performance Systems
-Lean Supply Chain Management
-Pareto Analysis

Deliverables:
-Classroom training
-Training documents

Administration:
Attendees will include floor staff, engineering and materials management

8.Inventory Management Training Course Outline

Overview: This course will provide the participants with a methodology to perform data gathering and analysis, inventory profiling and the ability to indentify the root causes of inventory skrinkage, loss and waste.

Key Learning Points:
-Roll Throughput Yield
-Pareto Analysis
-Loss recovery Analysis
-Corrective/Preventive Action Process

Deliverables:
-Classroom training
-Training documents
-Root Cause Analysis Program
-Corrective and Preventive Action Plan
-Implementation Plan

Administration:
Attendees will include floor staff, professional staff and supervision.

9.Supplier Management Training Course Outline

Overview: This course will provide the participants with a methodology to perform supplier development programs which incorporate certification and qaulification of suppliers and parts. Students will learn how to select suppliers, certifiy them and identify total cost of ownership of procured items and services.

Key Learning Points:
-Value Stream Mapping
-Replenishment models
-Value Engineering
-Supplier Performance Systems
-Lean Supply Chain Management

Deliverables:
-Classroom training
-Training documents
-Pilot Supplier Certification Program
-Supplier Performance Scorecard
-Administration:
-Attendees will include floor staff, professional staff and supervision.


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