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Certified Lean Practitioner Training Program

Qualifying People - Developing Future

virtual classes schedule

27th Feb 2021, 6th March 2021, 13th March 2021, 20th March 2021, 27th March 2021: Certified Lean Practitioner | Duration: 5 Days

About the course

Lean thinking is a widely adopted customer-facing improvement approach that can greatly simplify processes and improve performance in both manufacturing and service organizations. Effectively applying Lean principles and tools can significantly improve value-added productivity and reduce waste and associated costs. At the same time, these tools drive an improvement in customer service and satisfaction levels. The intensive five-days program gives participants a practical, hands-on, learning-by-doing experience, applying Lean methodologies in a simulated environment. This course is taught and facilitated by Lean practitioners, leaders, and coaches, each with multiple years of successfully applying Lean in business organisations.

Course objectives

Lean Manufacturing is a series of proven techniques that cause work tasks in a process to be performed with a minimum of waste resulting in greatly reduced wait time, queue time, and other delays. It involves identifying and eliminating non-value adding activities in design, production, supply chain management, and dealing with customers. Lean manufacturing means creation of more value with fewer resources, waste elimination & reduced lead time. The broad purpose of lean manufacturing is to increase the value of products which are being delivered to customer. System has to set target of reducing the cost for achieving this. It is more focusing on elimination of waste which are known as non value adding activities in all steps of chain.

Course content / outline

Day 1

Introduction

  • Introduction of Lean Manufacturing
  • History of Lean & TPS
  • 4-P model of Toyota
  • Introduction of 3-M
  • Introduction of 3-G
  • Introduction of 8 wastes of Lean
  • 5-W & 1-H model
  • Implementation Approach
  • Exercise – 30 Mins.

How to manage workplace

  • Introduction of 5-S + Safety
  • Types of Abnormalities
  • Introduction of Visual Management and Visual Control
  • Case Study
  • Exercise – 30 Mins.

Day 2

How to plan activities and material

  • Introduction of Value Stream Mapping
  • Process Mapping and Bottleneck Analysis
  • VA & NVA activities
  • Lead time, Takt time, Cycle time
  • Exercise – 30 Mins.
  • Introduction of JIT (Just in time)
  • Introduction of Heijunka (load levelling)
  • How to implement Heijunka (load levelling)
  • Exercise – 120 Mins.(Excel calculations)
  • Difference between Takt time, Lead time, Cycle time
  • Inventory Management
  • Flow Management
  • Inventory Control Techniques

Day 3

How to improve machine performance

  • Introduction of TPM (Total Productive Maintenance)
  • 8 Pillars of TPM
  • 16 Losses of TPM
  • OEE, MTTR & MTBF
  • Exercise – 60 mins.

Day 4

How to do improvement actions

  • Definition of problems
  • Root Cause Analysis
  • Introduction of A-3 Tracker
  • Case Study
  • PDCA approach
  • 3-C Action Plan
  • Case Study
  • Exercise – 60 mins.

How to do improvement projects

  • Introduction of SMED
  • Introduction of Jidoka
  • Introduction of ANDON
  • Exercise – 60 Mins
  • Specimen Paper – 60 Mins

Day 5

Continuous Improvement

  • Introduction of Kaizen
  • Principles of Kaizen
  • Kaizen cycle implementation
  • Introduction of Poka-Yoke
  • Exercise – 60 Mins.

How to sustain the improvement

  • Introduction to OPL/SPL
  • Introduction of Visual SOP
  • How to prepare 6-S reference
  • Introduction of My workplace
  • Introduction of DWM (Daily Work Management)
  • Introduction of Standard Work
  • Exercise – 60 mins.

Exercise - 25% Course time

Examination

Duration:

5 days

EVALUATION:

2 hrs.

Written examination:
 (Open book) at the end of the course.
Exam Type: MCQ (Multi Choice Question)
Total Marks for Examination: 100 (Passing Marks – 70)

*Submission of Case Study with monetary benefit sheet.

Certification:

Participants who score 70% and above in written examination will be issued a certificate for successful completion as a “Certified Lean Practitioner”.

Next Steps

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