Lean Manufacturing Certificate Program
Course Number: QCN E40 001
The demands of the market place in today's economy require, without fail, a quality product delivered on time at a competitive price. The Lean Certification program trains people in understanding and eliminating all forms of waste and improve productivity/efficiency while keeping sales and profitability high. Through hands-on exercises and simulation, participants learn the principles of Lean, how to identify nonvalue-added activities and how to apply Lean principles to unique situations.

Topics covered include:

• Value Stream Mapping -creates graphical maps of our organizations' current state and desired future state. From this information, an implementation plan is developed to aid the organization in going from the current to the improved state in a short period of time through the appropriate improvement projects (called Kaizen Blitzes). Many companies start with VSM in initiating the Lean journey.


• 5S in the Workplace - 5S is a system that will result in your shop-floor and/or office being maintained in an organized and efficient manner and is one of the basic building blocks of Lean. This program is designed to organize and standardize any workplace using a five-step method: Sort, Set in Order, Shine, Standardize and Sustain.


• Kaizen Blitz - How do we reduce changeover or set-up time, which is totally non-productive? Learn about the steps involved in cutting out non-value added activities so as to achieve the ultimate goal of equipment changeovers under ten minutes or what is called SMED (Single Minute Exchange of Dies). This Lean technique is implemented in a breakthrough Kaizen (continuous improvement) mode, called "Kaizen Blitz".


• Visual Factory System - A Visual Factory makes extensive use of simple signals that provide an immediate understanding of a situation or condition: whether it is normal or abnormal. Typically these controls are efficient, self-regulating and work managed. This Lean seminar will teach you how visual systems can improve activities on the shop floor as well as in the office. How visual controls can be used in Streamlined Layout, Standard Work, Point-of-Use-Storage, TPM, etc. will also be discussed.


• Lean Simulation 101 (8 hours) - The Lean Simulation is a "fun" way of introducing the concepts of Lean manufacturing. Topics include an overview of Lean manufacturing principles, reinforced with hands-on production simulation. Working in a mock company, "Buzz Electronics" participants assemble a "real" product on a simulated factory floor, incorporating the various Building Blocks of Lean along the way. By participating in the Lean Simulation, attendees learn how to use less manufacturing space and much reduced time and inventory to produce parts with fewer defects. Productivity, inventory turns, profitability and on-time delivery are improved. Working as part of a team, participants will quickly grasp the key concepts of Lean Manufacturing.


• Pull/Kanban - A system of cascading production and delivery instructions from downstream to upstream activities in which the upstream supplier does not produce until the downstream customer signals a need. Kanban is a unique information-carrying device that ensures that every operation produces only the amount of a product that will actually be used in the next step of the production process. Kanban serves as a trigger for production and conveyance (or withdrawal).


• Cellular/Flow Production - deals with the layout of machines of different types for performing different operations in a tight sequence, typically in a U-shaped pattern. Cellular production permits single-piece flow, line balancing and flexible deployment of human effort by means of linked multi-machines working efficiently based on "takt" time. Cross trained cell opertors may handle multiple processes and the number of operators is changed when the customer demand rate changes. This type of production is the most efficient Lean manufacturing method. Students will learn how to set up Lean cells, line balancing, "takt" time, calculating the number of workers needed, etc.


• Total Productive Maintenance is a series of steps to ensure that every machine in a production process is always able to perform its required tasks so that production is never interrupted. "Uptime" is maximized, along with machine performance and the first-pass-yield (or quality of the product). Overall Equipment Effectiveness (OEE) is enhanced through TPM.


• Lean Team & Change Management -"Lean" employs teams everywhere, both daily work teams and Kaizen (or Improvement) teams. Cultural change from the traditional to the Lean environment is essential for sustaining the Lean benefits and for Lean to become part of everybody's daily work life. These two topics (called "the Human Side of Lean") are critical for any successful Lean transformation. The participants will learn how Lean teams and cultural change can be implemented efficiently.


• Lean Office - Overview of Lean principles applied to office processes and procedures such as accounting, purchasing and sales/customer service. Learn to follow your systems through the identification of roadblocks and waste. Eliminating waste improves your processes, reduces wasted time and cuts costs, while increasing customer satisfaction and productivity. Wastes of Lean include: waiting time, incorrect/incomplete information, non-value-added processing, excess motion, and underutilized people. A must for people in the service industries as well as for any manufacturing company's office functions.


• Six Sigma and Lean Manufacturing - A beginner's overview of the principles of Six Sigma, a disciplined measure of quality that is data-driven. Methodology focuses on process improvement and strives for zero defects, using the Define-Measure-Analyze-Improve-Control (DMAIC) steps. Learn how Six Sigma compliments Lean Manufacturing.

To register or for more information please call
Triton College Continuing Education at 708-456-0300 ext. 3500.