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Lean Expert in Manufacturing allows the learner to develop an advanced level of knowledge about the implementation and integration of Lean Principles into every level of a manufacturing organization. The learner is taken through a systematic process using the “10 Steps to become a Lean Enterprise” model to help focus and prioritize all the implementation and integration activities. Lean Mfg. Training modules teach the same principles that are used in the Toyota Production System (TPS).

As a learner completes each of the twenty seven training modules, they will increase their knowledge and develop the ability to apply the “10 Steps to become a Lean Enterprise” model into any manufacturing environment. The Lean Expert in Manufacturing Course Objectives will allow you to view the training modules in each of the ten steps. Click on any of the links to read more details about a specific step on this page.

Lean Expert Traning Online


Level 3 – Lean Expert in Manufacturing Course Objectives:

Step 1 Strategy Deployment.
Step 2 Value Stream Mapping.
Step 3 Workplace Organization.
Step 4 Process Flow.
Step 5 Reduce Changeover Times.
Step 6 Pull System.
Step 7 Balanced Workload.
Step 8 Standard Work.
Step 9 Continuous Improvement.
Step 10 Lean Supply Chain.

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Step 1: Strategy Deployment – Four Parts:

Part 1 of 4: Upon completion of this course, you will be able to:
  1. Understand the use of the importance of the ISEE cycle.
  2. Participate in a Strategic development process.
  3. Develop and implement Breakthrough Objectives (BTO).
  4. Develop and implement Annual Improvement Priorities (AIP).
  5. Plan improvements over the next 12 months.
  6. Develop and implement Target Improvements (TI).
  7. Develop and implement Tasks.
Part 2 of 4: Upon completion of this course, you will be able to:
  1. Understand the Breakthrough Model.
  2. Understand the application an Enterprise PDCA.
  3. Understand the importance of establishing a feedback loop.
  4. Understand the purpose of an executive review.
  5. Understand common problems during SD implementation.
Part 3 of 4: Upon completion of this course, you will be able to:
  1. Understand the application of Strategy Deployment (SD).
  2. Understand the 3 levels of the SD Application.
  3. Determine key focus areas for improvement.
  4. Understand the tools of Strategy Deployment.
  5. Understand the Strategy Deployment planning and scheduling process.
Part 4 of 4: Upon completion of this course, you will be able to:
  1. Understand Quality, Cost and Delivery (QCD).
  2. Understand the five benefits of QCD.
  3. Understand the importance of QCD.
  4. Understand the seven key QCD metrics.
  5. Understand the five-step QCD process.
  6. Understand how to monitor process performance using QCD.
  7. Understand the QCD feedback process.

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Step 2: Value Stream Mapping – Three Parts:

Part 1 of 3: Upon completion of this course, you will be able to:
  1. Understand the 4 steps of Value Stream Mapping.
  2. Understand the purpose of Value Stream Mapping.
  3. Understand the Data Collection Process.
  4. Understand Step 1 of 4, identify Product Families.
  5. Understand Step 2 of 4, draw a Current State Map.
  6. Identify Opportunities for Improvements.
Part 2 of 3: Upon completion of this course, you will be able to:
  1. Understand the Value Stream Mapping data collection process.
  2. Understand how to draw a Current State Map.
Part 3 of 3: Upon completion of this course, you will be able to:
  1. Understand how to draw a Future State Map.
  2. Understand how to develop a VSM Implementation Plan.

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Step 3: Workplace Organization – Four Parts:

Part 1 of 4: Upon completion of this course, you will be able to:
  1. Understand the purpose of 5S.
  2. Understand each of the 5S activities.
  3. Understand the term “cross-functional team”.
  4. Understand each of the 5S tools.
Part 2 of 4: Upon completion of this course, you will be able to:
  1. Understand how to apply the 5S tools.
  2. Understand how to convert the 5S concepts into standard practices.
  3. Understand how to sustain all 5S improvements in the workplace.
Part 3 of 4: Upon completion of this course, you will be able to:
  1. Understand the definition of visual management.
  2. Understand the five levels of visual control.
Part 4 of 4: Upon completion of this course, you will be able to:
  1. Understand the visual management objectives.
  2. Understand the three I’s of visual management.
  3. Understand the visual management improvement cycle.
  4. Understand how to apply visual management techniques in the workplace.

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Step 4: Improve Product Flow – Two Parts:

Part 1 of 2: Upon completion of this course, you will be able to:
  1. Define process flow.
  2. Understand the reason for lead-time
  3. Apply Little’s Law to see how inventory affects lead-time.
  4. Identify where to begin to improve process flow.
  5. Understand how to draw a travel diagram.
  6. Understand the different types of workstation design.
  7. Understand how fixtures improve process flow.
  8. Understand how ergonomics affects workstation design.
Part 2 of 2: Upon completion of this course, you will be able to:
  1. Understand material replenishment.
  2. Understand the purpose of part presentation.
  3. Understand the different methods for delivering parts and materials to the work area.
  4. Understand the use of line side markets.
  5. Understand the principles of kitting for inventory and production control.

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Step 5: Reduce Changeover Times – Five Parts:

Part 1 of 5: Upon completion of this course, you will be able to:
  1. Understand the definition of changeover time.
  2. Understand the elements of a changeover.
  3. Understand the development of traditional changeovers.
  4. Understand the concept of an economic order quantity.
Part 2 of 5: Upon completion of this course, you will be able to:
  1. Understand the steps to improve changeover times.
  2. Understand how to document and record changeover activities.
  3. Understand how to separate changeover activities into internal and external
    elements.
Part 3 of 5: Upon completion of this course, you will be able to:
  1. Understand how to convert internal elements into external elements.
  2. Understand the importance of developing instruction sheets.
Part 4 of 5: Upon completion of this course, you will be able to:
  1. Understand how to streamline all aspects of the changeover operation.
  2. Understand function standardization.
  3. Understand the purpose of using intermediary jigs.
  4. Understand the use of parallel operations.
Part 5 of 5: Upon completion of this course, you will be able to:
  1. Understand Step 4 – Streamline all aspects of the changeover operation…continued from Part 4 of 5.
  2. Understand the application of functional clamping.
  3. Understand the need to eliminate adjustments.
  4. Understand the use of kitting to reduce changeover times.
  5. Understand the purpose of developing changeover instructions.

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Step 6: Implement a Pull System – One Part:

Part 1 of 1: Upon completion of this course, you will be able to:
  1. Understand the resource, batch size & inventory dilemmas.
  2. Understand a batch and queue process.
  3. Understand a single piece flow process.
  4. Understand the concept of a pull system.
  5. Understand how to link processes using kanban.
  6. Understand the purpose for using kanban.
  7. Recognize 3 types of kanban.
  8. Understand material replenishment using a pull system.

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Step 7: Balance the Workload – Two Parts:

Part 1 of 2: Upon completion of this course, you will be able to:
  1. Understand the principles of a balanced workload.
  2. Identify the two key focus areas for balancing the workload.
  3. Understand the data collection process.
  4. Understand how to analyze the data to balance the workload.
  5. Understand how to calculate takt time and apply it.
  6. Understand the formula for balancing the workload between operations.
Part 2 of 2: Upon completion of this course, you will be able to:
  1. Understand the heijunka load leveling process.
  2. Understand how heijunka improves the flow of products.
  3. Understand how to to apply heijunka to single or mixed model production.
  4. Understand how to implement load-leveling techniques.

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Step 8: Develop Standardized Work – One Part:

Part 1 of 1: Upon completion of this course, you will be able to:
  1. Understand the process of standardization.
  2. Understand how culture affects standardization.
  3. Understand the importance of standardized work.
  4. Identify the types of standard work tools.
  5. Explain how standard work documents are used.

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Step 9: Continuous Process Improvement (CPI) – Three Parts:

Part 1 of 3: Upon completion of this course, you will be able to:
  1. Define Continuous Improvement.
  2. Understand Problem Solving.
  3. Understand the how problem solving has evolved.
  4. Identify the different types of problems.
  5. Understand Management’s role in problem solving.
  6. Define a process.
  7. Understand the 8 Step Problem Solving process.
  8. Understand the A3 template and how to use it.
  9. Understand the problem solving tools.
  10. Understand the purpose of an A3 storyboard.
Part 2 of 3: Upon completion of this course, you will be able to:
  1. Identify the key problem solving tools.
  2. Understand the application of brainstorming.
  3. Understand the application of affinity diagrams.
  4. Understand the application of an impact-effort matrix
  5. Understand the application of flow charts.
  6. Understand the application of a data sheet.
  7. Understand the application of check sheets.
  8. Understand the application of run charts.
  9. Understand the application of histograms.
  10. Understand the application of pareto charts.
  11. Understand the application of cause and effect diagrams.
  12. Understand the application of scatter diagrams.
Part 3 of 3: Upon completion of this course, you will be able to:
  1. Understand the concept of kaizen.
  2. Understand the RIE procedure.
  3. Understand the purpose of high and low level events.
  4. Understand how to choose RIE team members.
  5. Understand RIE procedure activities.
  6. Understand how to create a RIE agenda.

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Step 10: Extend your Lean efforts into the Supply Chain – One Part:

Part 1 of 1: Upon completion of this course, you will be able to:
  1. Understand the importance of extending your Lean efforts into the Supply Chain.
  2. Define a Supply Chain.
  3. Understand how to develop a competitive advantage.
  4. Understand the difference between a “make to order” and “make to stock” process.
  5. Understand the purpose of a “tradeoff curve”.
  6. Understand the bullwhip effect.
  7. Understand the causes of the bullwhip effect.
  8. Understand Vendor Managed Inventory(VMI).
These online training modules cover the advanced application and integration of Lean principles into any manufacturing business model. The learner will be required to take an exam and achieve an 80% pass score to receive a Lean Expert in Manufacturing Non-Credit Certificate of Achievement.

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