What is Lean Practitioner and Lean Guide?

Understanding the Lean principles helps one identify what is of value to the customer. This identification feeds into removing all the “waste” and keeping only what is meaningful for the customer. You can create increasingly efficient processes with reduced costs and production time. One could say that Lean is a systematic approach to minimizing waste.

Background

Waste Elimination in a company leads to enhanced business results. Used rigorously by Toyota as TPS (Toyota Production System) and later known as Lean Manufacturing and Lean Management, this is one program that has the highest potential for transforming a company. We have conducted this course for 24 MBB Batches in the past.

Objective

To engage participants in seeing waste, understanding reasons for wastes and elimination of wastes. To provide hands-on practice on all the common lean tools and practices.

Why Benchmark Six Sigma is suited to deliver this program?

Benchmark Six Sigma is number 1 for Lean Practitioner and Lean Guide in many ways.

• In 2001, Benchmark initiated the first business excellence certification program in India. The only other provider in India at that time was Motorola University from the USA. The program has been evolving and is reviewed and revised every year. Lean Practitioner Competencies were a part of our Green Belt and Black Belt programs
• The Lean Practitioner and Lean Guide programs were initiated in 2006
• We train the largest number of business excellence professionals in Public and Corporate programs (1500+ every year)
• The large network of business excellence professionals has now crossed 40000. You can find a Benchmark Six Sigma certified professional in every large company in India
• We moderate the largest Lean Six Sigma learning community (among the top three in the world).
• Here are 15 key elements that differentiate us from others.

Offered as

a. Public Training – Calendar Program
b. Corporate Program – Standard or Customized, Continuous or Phase wise

Who Can Benefit

• Professionals who want to learn and apply the highly popular and successful Lean Principles and Practices
• Continuous Improvement Professionals
• Process Owners and Operation Managers
• Any progressive management professional who wants to bring change for the better.
• Anyone who wants to build competence that is domain independent

Training Package 

• Course Material Kit for Lean Practitioner and Lean Guide
• Data, Templates and Case Study for Analysis
• 3 Days of Instructor-led Classroom Training
• Lean Practitioner and Lean Guide Examination
• Globally Recognized Certificate with lifetime validity

Content Outline

LEAN PRACTITIONER OUTLINE

Lean Basics

1.     Lean Thinking, the origin of Lean Manufacturing, the focus on continuous flow.
2.     The journey – Batch processing, single piece flow and pure continuous flow.
3.     Understanding and visualizing wastes – TIMWOOD
4.     The meaning of Value Add and Non-Value-Add in a practical sense.
5.     5S as an improvement tool.
6.     PDCA cycles for continuous improvement.
7.     Kaizens and Kaikakus
8.     Identifying opportunities with As-Is Value Stream Map

Defining a mini project

1.  Selecting a Lean Practitioner Project.
2.  High-level mapping of the process – SIPOC diagram.
3.  Creating a mini charter.

Assessing current performance

1.  Lean Metrics – Cycle time, Takt time, Lead time, Throughput.
2.  Relationship of these metrics with each other and impact on productivity.
3.  Calculating process cycle efficiency.
4.  Working with set up and change-over times, The concept of SMED.
5.  Detailed mapping of a process with a swim lane map or a VA-NVA mapping
6.  Assessing OEE

Finding the root cause of a problem

1.  Gemba and Genchi Genbutsu
2.  Listing potential causes using an Ishikawa diagram. Using a mind mapping tool for the Cause-Effect diagram.
3.  Validating root causes with Why- Why analysis and Pareto’s analysis
4.  Using huddles and Kanban boards for team engagement during the project.

Finding alternative solutions and implementing the best solution

1.  Using lean principles to question the As-Is Value Stream Map
2.  Understanding and considering visual controls, supermarkets, Kanbans, Pull systems for the future Value Stream Map.
3.  Heijunka, Takt, Pitch and Runner systems.
4.  Visual control, Andon boards, and Kanban Boards

Ensuring Sustenance of the solution and CI after implementation

1.  Doing Risk Analysis
2.  Making use of Poka Yoke
3.  Using Kanban, Andon, and VSM as tools for continuous improvement.

LEAN GUIDE OUTLINE

1.     Implementing Lean with DMAIC framework.
2.     The psychology behind errors and mistake proofing
3.     Lean Principles
4.     Handling resistance
5.     Simulation Exercise
6.     VSM in Service Exercise

The contents of this program can be customized based on a shadow session or pre-study done within the company.

Lean Practitioner and Lean Guide programs with unmatched advantages