Lean Lead Facilitator Certificate

Lean principles and tools have resulted in significant process and performance improvements for organizations. Dramatic results have been realized, such as:

• Increased inventory turnover resulting in less inventory costs
• Increased on-time deliveries to customers
• Reduced lead times
• Reduced set-up times
• Improved quality
• Improved productivity
• Higher levels of customer satisfaction and delight

For more information on the benefits of Lean, go to: http://bec.msoe.edu/lean/

Organizations undertaking Lean are on a journey toward world-class performance. Through the journey, the Milwaukee School of Engineering’s Business Excellence Consortium works with the organization to guide them through the process and ensure benchmarks are attained.

The Lean Lead Facilitator Certificate is MSOE’s classic three-week program that has been updated to reflect customer feedback and new developments in Lean practices. It is a comprehensive training program for those who will be leading Lean teams within the organization. These are the individuals who will be selecting team members and conducting Kaizen events.

Modular Design

Lean Lead Facilitator has a modular design so that organizations and individuals can select only those specific Lean tools that fit their specific needs. Or, they can complete the three-week certificate for maximum benefit.

The MSOE Difference

MSOE is widely recognized for the quality of its education and its practical, application-oriented educational approach. These same principles apply to the Lean Lead Facilitator Certificate. Classroom sessions combine a powerful mix of instruction with hands-on experience. To further support the quality of instruction, those who successfully complete the Lean Lead Facilitator Certificate are also awarded academic credit from MSOE’s Rader School of Business.

Content

Lean Lead Facilitator is delivered in three one-week sessions, approximately every four weeks. For organizations, this can be modified to fit specific organizational requirements. Following is a description of each week’s topics and activities:

Week 1

• Lean Overview – 1 day
  A basic understanding of waste and inefficiency, a review of the major Lean tools, a rundown of how each tool is used, and an awareness of how Lean methodology supports business initiatives.

• 5S and Visual Management – 1/2 day
  More than just a "quick fix", proper 5S and Visual Management implementation leads to pride in the workplace while sustaining the improvements for cleanliness, organization, and safety.

• Process Flow  - 1 day
  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).

• Pull Systems - 1/2 day
  Proper Kanban design will simultaneously minimize inventory, while providing a materials management process that all employees can interpret and understand at a glance.
  
  
• Setup Reduction - 1/2 day
  Reducing setup times increases production capacity and improves customer satisfaction without adding resources and increasing costs.
  
  
• Total Productive Maintenance - 1/2 day
  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.
  
  
• Problem-Solving Tools – 1/2 day
  Learn all the basic problem-solving tools with a critical element – application.
  
  
• Error Proofing – 1/2 day
  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.

Week 2

• Value Stream Mapping - 3 day
  Utilize this visual tool that graphically identifies every process in a product’s flow, giving visibility to both the value-adding steps as well as the non-value adding steps.

• Kaizen Event Preparation and Facilitation – 1 day
  Learn the role a team facilitator and team leader play in conducting a Kaizen event and event follow-up.

• Presentation Skills – 1 day
  The basic tools for creating powerful presentations and training sessions using audio/visual aids, props, voice, and the human body.

Week 3

• Leadership Development – 1 day
  Develop leadership skills needed when implementing change. Focus is on why leadership and listening skills are essential in the change process.
  
  
• Team Building – 1 day
  Team leaders and team facilitators learn how to effectively challenge teams to achieve greater performance results
  
  
• Leading Change - 1 day
  Participants will learn how leaders impact the change process and the fundamentals of effectively leading an organization through transformation.
  
  
• Lean Office Deployment – 1 day
  Lean concepts will be applied to a transactional environment. Participants will learn how to deploy Lean by means of a “swim lane” value stream map.
  
  
• Presentation Workshop– 1 day
  Participants will present their presentations that were developed outside the class between Weeks 2 and 3. This will allow the participant to present and have the class evaluate assignment outcomes and presentation delivery skills.

Scheduling

Each week’s sessions are separated by approximately four weeks to enable participants to begin practicing the tools covered during a week-long session. In some cases, participants are expected to report on their Lean activities.

Outcomes

At the conclusion of this three-week program, participants:

• Understand the Lean methodology
• Be able to identify the 8 different forms of business waste
• Have an understanding of all the Lean tools
• Know which tool helps to eliminate which form of business waste
• Will have experience applying some of the Lean techniques
• Will be prepared to serve and support a Lean initiative
• Understand how to properly position and use a Kaizen event to obtain and sustain performance
• Be able to lead a Lean team