This
certification is good for 9 undergraduate credits or 6 graduate credits
at MSOE.
The
certification process consists of three parts: three weeks of classroom
experience, the experience of participating and running at least four
shop floor/office kaizen events, and finally participation in World
Class Company benchmarking trip.
PART
1
The
classroom experience consists of the following classes (the first two
weeks vary by certification business area; week three is the same for
all areas):
| |
Manufacturing |
Healthcare |
Administration |
| Week 1 |
Overview of Lean (1 Day) |
Overview of Lean for Healthcare
(1 Day) |
Overview of Lean for Administration(1 Day) |
| 5S/Visual Factory (1 Day) |
5S/Visual Factory (1 Day) |
5S/Visual Factory (1 Day) |
| Process Cells (1 Day) |
Team Building (1 Day) |
Team Building (1 Day) |
| TPM (1/2 Day) |
Visual Standard Work (1 Day) |
Visual Standard Work (1 Day) |
| Setup Reduction (1/2 Day) |
TPM & Setup Reduction (1/2
Day) |
Office Processing Cells (1/2 Day) |
| Team Building (1 Day) |
Inventory Kanbans (1/2 Day) |
Inventory Kanbans (1/2 Day) |
| |
| Week 2 |
Problem Solving Tools (1 Day) |
Problem Solving Tools (1 Day) |
Problem Solving Tools (1 Day) |
| Error Proofing (1/2 Day) |
Error Proofing (1/2 Day) |
Error Proofing (1/2 Day) |
| Kanbans (1/2 Day) |
Value Stream Mapping (3 Days) |
Value Stream Mapping (3 Days) |
| Value Stream Mapping (3 Days) |
|
|
| |
| Week 3 |
Advanced Team Building (1 Day) |
Advanced Team Building (1 Day) |
Advanced Team Building (1 Day) |
| Kaizen Event Prep & Facilitation
(1/2 Day) |
Kaizen Event Prep & Facilitation
(1/2 Day) |
Kaizen Event Prep & Facilitation (1/2 Day) |
| Leadership Development Day 1 (1
Day) |
Leadership Development Day 1 (1
Day) |
Leadership Development Day 1 (1 Day) |
| Leadership Develepment Day 2 (1
Day) |
Leadership Develepment Day 2 (1
Day) |
Leadership Develepment Day 2 (1 Day) |
| Leading Change (1/2 Day) |
Leading Change (1/2 Day) |
Leading Change (1/2 Day) |
| Presentation Skills (1/2 Day) |
Presentation Skills (1/2 Day) |
Presentation Skills (1/2 Day) |
COURSE DESCRIPTIONS:
Overview
of Lean
Proof
of the need to change and adopt Lean, a description of the Lean tools,
and a simulation comparing batch vs. flow production
5S/Visual
Enterprise
A
5S/Visual Enterprise implementation leads to improved pride, quality,
and productivity in the work place while sustaining the improvements
for safety, cleanliness, and organization. Includes a 5S exercise/simulation.
Team
Building
Learn
the requirements for teamwork to occur, develop an understanding of
team dynamics, how teams positively impact productivity, and the impact
of effective communication in a team environment. Includes a team building
exercise.
Total
Productive Maintenance
With
operator involvement as the foundation, the plant-wide role changes
required to support TPM are established as the starting point on the
journey to zero unplanned downtime.
Setup
Reduction
Reducing
equipment setup times improves production capacity, reduces product
lead-times, and improves customer satisfaction without adding resources
or increasing costs.
Process
Cells
Gain
exposure to the tools, thought processes, and support systems required
to design and implement one-piece flow (including calculating takt time
and standardizing work practices).
Problem-Solving
Tools
Learn
all the basic problem-solving tools with a critical element - application
using a simulation.
Error
Proofing
Gain
a complete understanding of what error proofing is, how it is used as
an improvement strategy and how to analyze a problem for error proofing
potential. Includes error proofing exercise.
Inventory
Kanbans
Proper
Kanban design will simultaneously reduce inventory, improve customer
service levels, eliminate part outages and shortages, while providing
a materials management process that all employees can interpret and
understand at a glance.
Value
Stream Mapping
(VSM)
Utilize
this visual tool that graphically identifies every step in a product's
flow, giving visibility to both the value-adding steps as well as the
non-value adding steps. Completed on an actual host company process.
Advanced
Team Building
Team
leaders and team facilitators learn how to effectively challenge teams
to achieve greater performance results
Kaizen
Event Preparation and Facilitation
Learn
the role a team facilitator and team leader play in conducting a kaizen
event and event follow-up
Leadership
Development Day 1
Develop
leadership skills needed when implementing change. Focus is on why leadership
and listening skills are essential in the change process.
Leadership
Development Day 2
A
continued development of leadership skills. Focus is on why empowerment,
motivation, and attitude are essential in the change process.
Leading
Change
Participants
will learn how leaders impact the change process and the fundamentals
of effectively leading an organization through transformation
Presentation
Skills
The
basic tools for creating powerful presentations and training sessions
using audio/visual aids, props, voice and the human body
PART
2 (After
the classroom sessions and at the facilitator's home site) :
Developing
a world class environment -
1 day
Provide
an implementation plan that clearly identifies areas for focused improvements
and why, who owns the actions, how the improvements are to be measured
and a timeline for actions to include training and improvement events.
Act
as a team leader during a Kaizen event while being evaluated for certification
-
3-5 days
While
serving as team leaders, participants are evaluated by a BEC coach on
their facilitation skills while receiving coaching to help them improve
team facilitation and empowerment.
Conduct
two in-house Kaizen events -
3-5 days each
Kaizen
leaders must submit pre-event paperwork prior to the event for support
and post paperwork for event documentation and evaluation.
Facilitate
a Kaizen event while being evaluated for certification -
3-5 days
While
conducting a Kaizen event a BEC coach evaluates the Kaizen leader on
their ability to plan and lead a Kaizen team through the 15-step Kaizen
process while achieving and maintaining the desired event outcomes.
(Participant is evaluated on presentation skills that are required during
the Kaizen event's training process).
PART
3 (After
the Kaizen Event training) :
Participate
in a benchmarking tour of a World Class organization -
1 day
Tours
of Toyota and other World Class organizations are setup by WCM Associates
Upon
completion of the Lean Master Facilitator Certification, participants
will:
*Be
able to develop, with the executive team, the key metrics that
drive organizational improvement
*Have the knowledge to
lead an organization's Lean initiative
*Have a complete understanding
of the Lean tools and the ability to be able to apply those
tools to specific organizational objectives
*Know the importance of
associate empowerment through a team-centered environment
*Understand the role of
the customer and know how to increase customer satisfaction
*Be able to train fellow
associates on the tools of Lean
*Be able to facilitate
improvement activities including Kaizen events
|
