Certified Lean Facilitator Training: 3-Week Program

WCM Associates LLC offers a Certified Lean Facilitator Program, a comprehensive training program for those who will be leading Lean teams within the organization. The program includes an in-depth understanding of the Lean Tools along with how to successfully apply the Lean Tools through a team-centered leadership style. The goal of this program is to allow companies to develop in-house Lean experts so they do not have to rely on consultants for the long term. For companies to implement and integrate Lean as a system, they must “own” Lean.

The certification process consists of three parts:

  • Three weeks of classroom experience (outlined below)
  • The experience of participating and running at least four shop floor/office kaizen events
  • Participation in a World Class Company benchmarking trip.


Part 1: 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.
 
Visual Standard Work Visual Standard Work are the visually documented methods for people and machines to work together to produce a quality product/service while minimizing all forms of waste. Visual Standard Work documents the safest, best, and easiest way to do a job. It focuses on the process procedure (not the person or the outcome). Visual Standard Work includes: Takt Time and Pitch, Work Distribution and Sequence, and Job Instructions/Standard Work Sheets.

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).

A3 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 and Policy Deployment 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 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 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 Certified Lean Facilitator program, 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

 

View our current schedule of publicly held training courses.

Or, contact us about hosting a session at your facility!