Certified Lean Foundation & Practitioner

Gain an understanding of the control framework of eight Ds in Lean.
Learn how to utilise time, cost, and quality metrics.
Understand visual management, advanced VOC, and lean metrics.

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Certified Lean Foundation & Practitioner

Overview 1

Outlines 2

FAQs 3

What's Included 4

Course Overview

Lean is a program management approach whose ultimate goal is to enhance and create more value for customers with fewer resources. A lean organisation understand how to provide the absolute value to the customer, which contains zero waste. It plays vital roles in many organisations in improving customer satisfaction by achieving quality goals and objectives. This two-day training course design to provide delegates with the knowledge of Lean’s key concepts and how they apply to real-world organisations.

In this training course, delegates will gain an understanding of reviewing processes and identifying problems, finding and eliminating waste, and reducing defects. They will also learn the various topics in this Certified Lean Foundation & Practitioner course such as key terms of lean, origin of lean, six significant losses, key lean metrics, steps of 5S, value stream analysis, visual management, and total productive management. Our training will help delegates to become confident Lean Practitioner with in-depth knowledge of its methodologies.

Course Outline

Lean Foundation

Introduction to Lean

What is Lean?
The Path to Value
Key Terms and Concepts of Lean
Gemba
- Gemba The Real Place
- Gemba Tools and Walk
Process Stapling
Kaizen
Hoshin Kanri (Policy Deployment)
Jidoka (Autonomation)
Just in Time (JIT)
Six Big Losses
TPM: Total Productive Maintenance
Lean in a Nutshell
- The Lean Temple
- The Lean Business
- Uses of Lean
What’s Changing at Service Companies?
Origins of Lean
Customers, Processes, and Waste
What are Customers?
What is the Process?
The Focus
Tension Between VOB and VOC
What Do We Mean by Value?
The Path to Value
Dealing with Values
The Eight Wastes of Lean
Key Lean Metrics
Tools and Techniques
The Lean Triad

5S Training

What is 5S?
The Steps of 5S
Tips for 5S
Define Poka Yoke
Understand SMED
Voice of Customer (VOC)
- Customer Segmentation
- Define SIPOC
- Overview of the Kano Model
Value Stream Analysis
- Value Stream Terminology
- Process Maps
- Swim Lanes
- Process Mapping
- Typical Process Map Contests and Symbols
- Value Stream Maps
Heijunka in a Nutshell (Day 2)
- Process Levelling Overview
- Production Levelling
- Demand Levelling
- Sequencing and its Concepts
What are Kanbans?
Three-Bin System
Kanban Operation Rules
Benefits of Employing a Kanban Series
Andon
Pull Systems and Kanban Summary
Identifying Root Causes
Seven Key Steps in the Use of a Fishbone Diagram
Fishbone
Problem Solving
- Problem Solving Framework
- Prioritisation Tools
Control Frameworks
- The Three C’s
- The Eight Ds
- Plan Do Check Act
- Introduction to Kaizen
Lean Teams
- High Performing Teams (HPT)
- Managing Progress and Demonstrating Control

Lean Practitioner

Maintaining and Building Lean Teams

The Role of the Team Leader
Managing Teams
- Work Cells
- Lean Management
- Self-Managed Team Philosophy
What is Personality Style?
High Performing Teams (HPT)

Visual Management

Introduction and Guidelines to Visual Management
Cell Information Boards
Visual Communications and Documentation
Operations Control and Team’s Territory
Visual QC and Making Progress Visible
Process Indicators and Implementation
Visual Management Checklist

Advanced VOC

Advanced Intelligence Methods
Critical to Quality Trees

Lean Metrics

What are the Metrics?
Measures and Targets
Metrics Drive Behaviour
Traditional vs Lean Metrics
Choosing the Right Metrics
Useful Metrics
Metrics and Measures Roadmap
Key Metrics

Process Measurements

What Are Lean Process Measurements?
First Time Quality
Rolled Throughput Yield (RTY)
Completed Orders Metrics
- Delivery Metrics
- Warranty Metrics
- Customer Feedback Metrics
- Reporting Metrics
Aims of Data Collection
Key Performance Indicators
- Measurement
- The Focus
- Process Measurement Points
- List of Criteria for a Good Measure
- Gauge R and R
- Measurement System Resolution
Brief Description of Data Collection Planning
- Five Steps of Data Collection Process
- Data Collection Sheet
- Frequency and Sample Size
- Evolving Your Data Collection Plan

Total Productive Maintenance

TPM in a Nutshell
What is TPM?
TPM: Goals
TPM and Teamwork
Why is TPM Needed?
The Benefits of TPM
TPM
- What To Focus On?
- Where Should it be Applied?
- Maturity Levels
- Health Check (Capability Assessment)
Implementation Structure of TPM

Process Levelling

Define Process Levelling
Level Scheduling: The Concept
- Process Levelling (Theory)
- Process Levelling: Demand Management
- Resource Scheduling: Simon’s Coffee Bar
- Theory of Constraints
Just in Time
Total Productive Maintenance
Variance in Takt Time
Process Levelling in the Office
Water Spider
What is the Minimum Cycle Time for a Form?
Putting it All Together
Purchasing Department: Before Lean
The Lean Office: How it Was
Purchasing Department: After Lean
The Lean Office: Putting it All Together
Purchasing Department: The Lean Environment

Value Stream Mapping

Process Maps
Advantages of Visual Mapping
Swim Lanes
Process Map Levels
On the Ground Instructions (OTGIs)
Value Stream Maps
Investigating and Understanding the Process
Creating an Improved Process
Identify Areas of Improvement
Building Your Paper to the Required Standard
Points for Facilitators
Process Mapping Closedown
Identifying Priorities: Effort/Impact Grid

In this Certified Lean Foundation & Practitioner course, there are no formal prerequisites.

This Certified Lean Foundation & Practitioner course design for anyone interested to develop their knowledge of the Lean methodology. It is much more beneficial for: