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Lean Practitioner

Lean Practitioner I Certification Program

Boot camp – A non-threatening environment where participants present lean materials in front of their peers and answer questions from facilitators. Participants are video taped and trained in presentation skills. Participants are also trained in lean auditing skills.

Who should attend?: Lean specialists that want to become Masters
Purpose: Solidify understanding of lean materials
Benefits: Participants will be able to train the trainers for lean implementations upon completing course requirements and be able to demonstrate ability to implement lines on their own
Caution: Suggest individuals should be considered “high potentials” in your organization. Consider employment contracts or non – compete agreements and a development plan for these individuals after they attend the class. Should be a minimum of a two-year commitment by the team members.
Course Length: 1 Week
Course Content: Total Lean Content
Course Fee: See Price List. Per person plus expenses. Training room and meals to be furnished by the Client
Max Participants: 10
Prerequisites: Lean Seminar III or Lean Seminar IV, three implementations, suggested reading list, thorough understanding of the materials and tools

Lean Practitioner II Certification Program

Who should attend?: Lean specialists that are Certified to lead a Lean 3 to 5 Hour Shop Floor training class

Purpose: Upon completion, participants will be able to successfully Implement one line on their own as well as to demonstrate proficiency in all Phase 2 activities on Lean Product Status Matrix including but not necessarily limited to:

  • Value Stream Map
  • Stake holder analysis
  • Standard Work/ Job sheet
  • Month by Day in place and tied to productivity
  • Changeover analysis and implementation
  • Disposition all stockroom material and relocate to the line, adjust material warehouse bins and shelf locations as needed and labeled
  • Day by hour in place with plan
  • Order Staging rack in place
  • Six S the Line and put Six S sustainability board in place 

Prerequisites: Certified  as Lean Practitioner Level 1 

Lean Practitioner III Certification Program

Who should attend?: Lean specialists that are Certified to train a Lean One Day class on their own

Purpose: Upon completion, participants will be able to demonstrate proficiency in all Phase 3 activities on Lean Product Status Matrix including but not necessarily limited to:

    • Creating a PFEP
    • Implementing Kanbans
    • Implement a VMI system at the line
    • Create a pull system from FG to the line and from the line to sub assy process or supplier
    • Conduct Six S, Standard Work, Heijunka and Lean Line audits
    • Implement a mistake proofing  project
    • Ten cycle analysis
    • Convert order staging to heijunka and past due rack
    • Day by Hour issues tied to QDIP
    • Warehouse materials labeled

Prerequisites: Certified as Lean Practitioner II

Lean Practitioner IV Certification Program

Who should attend?: Lean specialists that are Certified on 3 different sections of the 5-day

Purpose: Upon completion, participants will be able to demonstrate proficiency in all Phases I to 3 in all environments; Pass the Lean Specialists Exam; and read the following books:

    • Lean Thinking or Lean Transformation or Gold Mine or Andy and Me
    • Shingo green or black book
    • Toyota Production System – Ohno
    • Toyota Way
    • Toyota Kata
    • Choice of Making the Numbers Count or Who’s Counting

Prerequisites: Lean Practitioner III

Lean Practitioner V Certification Program

Who should attend?: Lean specialists that are Certified to train a 3 or 5-day Class on their own

Purpose: Upon completion, participants will be able to demonstrate proficiency in all Phases I to 4 in all environments; Benchmark 2 Lean Facilities; Pass the Lean Master Exam; and read the following books:

    • A3 Thinking or Managing to Learn
    • Toyota Production System (Monden)
    • Kanban Just in Time at Toyota (Ohno)
    • Creating a Lean Culture
    • Training Within Industry
    • Leadership Road Map
    • Toyota Culture

Prerequisites: Lean Practitioner IV

Lean Practitioner Training Implementation

This is a three month hands on pilot implementation by a pilot team at your company. This approach is based on your team attending four weeks of intensive training over a three month period. The training is a time released approach to provide the team training in subsets of lean manufacturing and then have the team go implement and bring deliverables to the next training class. The implementation will consist of seven to eight weeks of teams implementing on the shop floor. We can assist you if needed during these implementation weeks. Teams will build a complete case study and be certified as lean specialists at the end of the course subject to meeting some additional criteria.

Companies pick a pilot implementation prior to training. Team attends four weeks of intense lean training with seven to eight weeks of hands on implementation in the factory. Requires management support, leadership, all employee overview, pilot team overview, communication plans etc. Should be considered long term commitment that never ends.

Who should attend?: Lean Pilot implementation team

Purpose: To train a selected group of individuals on a company team how to implement a lean manufacturing line

Benefits: Significant savings on pilot implementation, Trained company lean specialists, which will need a minimum of consultant help, total transfer of as much consultant knowledge as team can absorb

Caution: Suggest individuals should be considered high potentials in your organization. Consider employment contracts or non – compete agreements and a development plan for these individuals after they attend the class. Should be a minimum of a two-year commitment by the team members.

Course Length: Eleven to Twelve weeks

Course Content: Very detailed course on how to implement lean manufacturing techniques. Participants actually lean out a line or part of a line in their factory

Course Fee: See price list – per person – plus any expenses. The company provides training area and meals.

Max Participants: 24 (minimum of two persons team from a company)

Prerequisites: World Class Criteria assessment, Consultant tour of factory, One day or Five day lean overview course attended by Senior Leadership, Consultant assistance in pilot selection.