Certified Lean Practitioner Training Program

A practical, hands-on, learning-by-doing experience, applying Lean methodologies in a simulated environment

A practical, hands-on, learning-by-doing experience, applying Lean methodologies in a simulated environment

virtual classes schedule

25th - 28th July 2022: Certified Lean Practioner - Expert Level | Duration: 4 Days | Time: 9:30 am to 6:30 pm

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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

 

  • Certified Lean Practitioner

    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

    CERTIFICATION

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

  • Certified Lean Practitioner - Expert level

    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
    • Exercise – 30 Mins.
    • How to apply lean concept in Service sector and support functions like purchase, HR, Finance, store, planning etc.
    • KPI
    • TEAM
    • SMART goal setting
    • Exercise – 15 mins
    • 5-W & 1-H model
    • Implementation Approach
    • Exercise – 30 Mins
    • Lean Implementation project selection matrix

    How to Manage Workplace ?

    • Brain storming Game – 15 mins
    • Introduction of 5-S + Safety
    • Types of Abnormalities
    • Introduction of Visual Management and Visual Control
    • Introduction to OPL/SPL
    • Introduction of Visual SOP
    • How to prepare 6-S reference
    • Introduction of My workplace
    • Case Study
    • Exercise – 30 Mins.

    Day-2

    How to level load & plan material ?

    • Inventory Management
    •  Types of Inventory
    • Inventory related cost
    • Inventory Control Techniques
    • Inventory Management Exercise – 120 Mins. (Excel base calculations for ITR, Safety stock, EOQ, Min-Max level, Re-order point, Re-order Quantity, Vendor selection)
    • Introduction of SMED
    • How to do PULSE mapping in SMED ?
    • How to apply SMED concept ?
    • SMED Exercise – 30 Mins
    • Introduction of JIT (Just in time)
    • Introduction of Heijunka (load levelling)
    • How to implement Heijunka (load levelling)
    • Heijunka Exercise – 30 Mins.(Excel calculations)

    Day-3

    How to map the process, material & Information flow ?

    • Introduction of Value Stream Mapping
    • Process Mapping and Bottleneck Analysis
    • VA & NVA activities
    • Exercise – 60 Mins.
    • Difference between Takt time, Lead time, Cycle time
    • How to calculate crew size
    • Exercise – 15 Mins
    • Introduction to Flow Management
    • Introduction to KANBAN
    • Specimen Paper – 60 Mins

    Day-4

    How to improve Equipment Performance ?

    • Introduction of TPM (Total Productive Maintenance)
    • 8 Pillars of TPM
    • 16 Losses of TPM
    • OEE, MTTR & MTBF Calculations – 30 Mins
    • Breakdown data analysis Exercise – 30 mins
    • Introduction to Jidoka
    • Introduction to ANDON

    Day-5 

    Continuous Improvement

    • Pareto Analysis
    • Root Cause Analysis
    • Exercise – 45 Mins
    • Introduction of Kaizen
    • Principles of Kaizen
    • Kaizen cycle implementation
    • Introduction of Poka-Yoke

    How to track Project Progress ?

    • Introduction of A-3 Tracker
    • PDCA approach
    • 3-C Action Plan
    • Introduction of Standard Work
    • RACI (Responsible, Accountable, Consulted, Informed) Matrix
    • Stake holder benefits
    • Exercise – 30 Mins

    Exercise – 20 % Course time

    Online Examination – 120 Mins 

    Certification

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


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)

 

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