Duration
Certified Lean Practitioner
5 days
Course aim
The programme is designed to equip shopfloor operational personnel on the fundamental concept and tools in Lean manufacturing.
BSI Certified Lean Practitioner Programme is accredited by The Council for Six Sigma Certification (CSSC)
Course description
The Lean Practitioner certification programme is a programme that has been designed to bring the delegate through from basic understanding of Lean to successful implementation of essential Lean tools in the workplace. The tools and techniques introduced in this programme have been successfully applied in manufacturing and service organizations and have resulted in significant monetary savings and improved operational performance.
How will I benefit?
This programme provides the foundation for the Lean Practitioner to:
- Identify wastes in the workplace
- Improve the organization of the work area
- Identify opportunities that can enhance the organisation’s ability to provide
value to its customers
- Carry out work study on specific tasks and identify opportunities for improvement
What will I learn?
Upon completion of the programme, participants would be able to :
- Explain Lean principles and techniques
- Show the ability to use relevant Lean techniques to eliminate wasteful practices
- Proceed to carry out Lean improvement projects
- Report key performance metrics to monitor progress and results attained
Who should attend?
Managers, Engineers, Maintenance and Production Supervisors and Executives responsible for process improvement
Duration
5 days
How will I learn?
The programme will be facilitated by experienced trainers who are also certified Lean Masters. Our experienced tutors have practical application of the subject matter, enabling them to understand and meet your specific requirements.
What will I gain?
On completion of Lean Practitioner Training, with a minimum attendance of 90%
per flight, you will receive an internationally recognized BSI certificate of attendance.
Lean Practitioner certification requirements (Certified Lean Practitioner)
- Completion of Lean Practitioner Training with a minimum attendance of 90% per Flight
- Pass Lean Practitioner exam
- Completion of 1 Lean project within 24 months of course completion
- Project report submitted to and approved by BSI trainer
- Project savings / benefits achieved to be validated and endorsed by participant’s
organization.
Participants must be involved and contribute (analysis and implementation) to the Lean Project either as team leader or team member.
Agenda
Lean Practitioner - Flight 1
Day
Time
Details
Day 1
09.00 am – 09.30 am
Opening and Introduction (Trainer & Participants)
Introduction to the Lean Practitioner programme
09.30 am – 10.30 am
Lean Manufacturing Value Stream Improvement
An Introduction to Lean
Why should organizations go Lean
10.30 am – 12.30 pm
Value Versus Waste 7 Operational Wastes
Principles to Lean transformation
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Overview of Lean tools and techniques
03.30 pm – 05.00 pm
Lean Simulation Workshop
Day 2
09.00 am – 10.30 am
Value Stream: Unlocking your Process Value Stream Tools
- Spaghetti Diagram
- Process Flow Activity
10.30 am – 12.30 pm
Workshop on spaghetti diagram and process flow activity
Learn to See - Current State
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Workshop on Current State
Improvement from Current to Future State
03.30 pm – 05.00 pm
Performance metrices from the value stream Summary and Q&A session
Day 3
09.00 am – 10.30 am
Work Engineering for Smooth Flow Manufacturing
Introduction to Work Engineering Work Method study
Motion study and Process Study
10.30 am – 12.30 pm
Principles and Tools to improve work method
- Principles of motion economy
- ECAS
Work Measurement
- Time Study - Normal time and Standard Time
- Work sampling - Normal time and Standard Time
- Cycle Time, Takt Time, and Lead Time
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Applications of IE Work Study
- Determine manpower
- Line Balancing (Yamazumi chart)
Developing the preferred method
- Work Element Analysis
- Multiple Activities Chart
03.30 pm – 05.00 pm
Group Simulation
Day 4
09.00 am – 10.30 am
Standardized Work
- Standard Work Sheet
- Standard Work Combination Sheet
10.30 am – 12.30 pm
Introduction to Smooth flow
- Purpose and benefits of flow based manufacturing
- Smooth Vs Disruptive Flow
Smooth Flow Manufacturing
- Types of assembly line layouts
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Smooth Flow Manufacturing (Con’t)
-Cellular Manufacturing (work cell design and planning)
- - Cell cycle time and capacity
Types of Flow Patterns
03.30 pm – 05.00 pm
Types of Flow Patterns Summary and Q&A
Lean Practitioner – Flight 1
Day
Time
Details
Day 5
09.00 am – 10.30 am
Kaizen Implementation
The background of Kaizen concept
- What does ‘kaizen’ mean
- the objective of Kaizen Project Selection and Kaizen Metrics
Two approaches to carry-out kaizens
- Kaizen Event
- Workplace Kaizen (Small Group Activities)
10.30 am – 12.30 pm
Organizing Kaizen Event :
- Kaizen Event Timeline
- Preparation: Project Charter
- Step-by-step guidelines with Kaizen Workbook
Organizing Workplace Kaizen (Small Group Activity)
- SGA Workbook
Calculating financial savings:
- Hard Savings
- Soft Savings
- Net Working Capital
12.30 pm – 01.30 pm
Lunch
01.30 pm – 03.30 pm
Flight 1 Lean Knowledge Assessment
03.30 pm – 05.00 pm
Flight 1 Lean Knowledge Assessment – Con’t
Programme scope, delivery arrangements and suitability are confirmed during enquiry.