Lean Practitioner Program
| Selected references |
Automotive
| Joyson | Fehrer | Continental |
Food
| Illy | Mars | Dr. Oetker |
Services & Retail
| E.ON | Auchan | Avis Car Rental |
healthcare
| Coloplast | Mylan | Ipab di Vicenza |
Gas & chemicals
| Pietro Fiorentini | MOL | Hexion |
Key highlights / Benefits from this program
- Famous and successful worldwide certification: over 3000 people trained so far
- Based on strong lean bases: part of the University of Barcelona postgraduate MSc program
- Developed by 18 different countries – take into account all relevant local factors
- PDCA evolution of training itself
- No limits of application for different fields of business – service, production, banking,..
- Strict criteria to achieve certification – real proof of understanding and ability to bring benefits
- Program is paid by itself – to be selected project with minimum benefit as the cost
| Basic information |
I. Who we are – Lean Global Network (LGN)
LGN is a community of lean thought leaders and practitioners with the goal of making things better by advancing lean thinking and support lean transformation around the World through education, coaching, action research, events and learning materials. Founded by Jim Womack and Dan Jones in 2007 with Headquarters in Boston, USA. Today, LGN is comprised of 30 institutes or partners and dozens of co-learning partners across the globe: http://leanglobal.org/affiliates/
Our definition of Lean Thinking & Practice:
Systematically develop people and continuously improve processes to provide value and prosperity while consuming the fewest possible resources.
II. The Lean Practitioner Program (LPP)
The 10 days Lean Practitioner Program was developed by the 18 LGN Affiliates as a certification program to combine the knowledge and skill development and to respond to the companies’ challenges on their lean journey. Providing this course we also generate new lean knowledge and share with other lean practitioners in the spirit of continuous improvement and PDCA and to further develop the LGN Lean Practitioner Program.
This curriculum is also part of the University of Barcelona postgraduate MSc program (Organization and Engineering of Industrial Plant Production and Management (ENGIPLANT).
When? March 2021
Where? 2 host companies (Slovakia – Syráreň Bel Slovensko / Hungary – TBD)
Who? Anyone who want to achieve impressive improvements in your business in a Lean way: teamleaders, process engineers, CEOs, production managers, branch managers,..
Price: 3.300 Eur* / participant / certification (*we are not VAT payer, price is total)
Price includes: Certified trainer, Printed certificate, Books for mandatory reading, coaching support, catering (coffee breaks, lunches)
Payment condition: Full prices to be payed maximum 1 month before realization of first day of LPP, official order necessary
| Content |
- 13 training modules in 10 days (2+2+2+2+1+1) in about 4 months duration
- Homework between each set of training days
- Additional readings (mandatory and suggested)
- Project execution
- Exam (theory and application)
- Project Presentation
| Subject | Content | Timing |
|---|---|---|
| History of lean | Where does lean come from | Day 1-2 |
| Intro to lean | What is lean; Toyota Principles; The 5 principles | |
| Intro to Problem Solving | Problem Solving; PDCA process; A3 framework | |
| Time definitions | Customer time definitions; Process time definitions; Equipment time definitions; Operator time definitions | |
| Stability | OEE measure; Six Losses; Capacity analysis | Day 3 |
| JIDOKA | Concept; Importance of JIDOKA; Implementation method | |
| Standard Work and Job Instructions | Concept; Simulation of a Job Instruction; Standard Work Study; Single Minute Exchange of Dies (SMED) | Day 4 |
| Value Stream Mapping (VSM) & Just In Time (JIT) | Concept; Current state – Value Stream Map (as is)Future state – Value Stream Map (to be); Simulation | Day 5 |
| Visual Management | Concept; Workplace organization; Visual signals; Visual measures; Visual controls | Day 6 |
| A3 and Problem solving | A3 framework; Plan phase; Do phase; Check-Act phase | Day 7 |
| Supplying the process | Right information; Right material; Right quantity; Right place; Right time | Day 8 |
| Kaizen | Purpose of Kaizen; Kaizen and People; Kaizen and Process; Outcomes | |
| Project with A3 | Coaching | Day 9 |
| Exam / Project presentation | Theory and application | Day 10 |
| Bibliography |
Mandatory readings
- Toshiko Narusawa and John Shook: Kaizen Express
- Mike Rother & John Shook: Learning to See
Suggested readings
- John Shook: Managing to Learn
- Mike Rother & Rick Harris: Creating Continuous Flow
- Rick Harris: Making Materials Flow
| Certification |
Certification of the Program
This certification in lean studies is equivalent with the Six Sigma Green Belt level.
What do we mean by certification?
- By certification we acknowledge that the participant has shown that he/she understands the lean system and is able to apply the methods and tools at a practitioner level
What will be certified?
- Knowledge of the theory (from the mandatory readings and the presented material)
- Skills in applying lean in a project (foundations to run a project, run kaizens, transfer knowledge to others, change management)
How is realized certification process?
- The certification consists of a written exam (1 hr; 10 open questions) and a presentation and discussion of the project work presented on A3 paper (1.5 to 2 hours)
Competencies acquired from the program
- Ability to identify value and waste
- Skills in leading and conducting PDCA and Kaizen
- Understand the importance of time (takt time, cycle time, etc.) and calculate them
- Ability to break down the work, recognize the elements and time, balance work and create standard work
- Understand and draw the current state value stream, find the improvement opportunities and create future state
- Understand the FLOW and PULL concepts
- Understand and improve efficiency (OEE) including improving available working time and understanding the importance and process of set up reduction
- Create a daily performance board and use it as an improvement tool
- Understand and implement 5S
- Create visual management system
- Create and present A3, Create and prioritize action plan
- Basic design and implementation of a JIT system
- Create Plan For Every Part (PFEP)
Requirements of the project the participant has to deliver for certification
- The project has to be ‘end-to-end’ based on a real business challenge and had an impact
- It has to be structured following the A3 structure (you may present multiple A3s if it is appropriate)
- The elements of the Toyota Business System should be used in the project
- As well as running a project, the participant should be able to engage other people in their project, transfer knowledge and create a sustainable situation
- Participant should be able to have a significant influence on the project
