Lean Master Certification are true kaizen “learn-then-do” events. By combining classroom training and practical hands-on experience, participants will learn more in one week than they ever thought possible. During intense sessions ranging from four to five days, participants experience real world situations as part of implementation teams working in pilot areas on the shopfloor or in the office. These programs are dynamic learning experiences that take the participant directly into the “hands-on” “real world” of a work-place. The learning objective of these workshops is not simply to teach, but to enable participants to participate, innovate and implement, with the ultimate goal of showing you how to bring these Lean methodologies successfully into your own company. Working in a different environment helps participants to “think outside of the box” and see things in a new light without any pre-existing paradigms.

The last day of each Master Series module consists of team presentations. Each team shares their experiences, the obstacles they overcame, and the successes they achieved. Participants then return to their own company with “new eyes,” new ideas and a working knowledge of how to create change in their own workplace by conducting their own kaizen events.

Module1: Cell Design and Management

Reduce lead time, reduce processing time, increase quality, reduce work-in-process and eliminate waste. The Cell Design & Management Master Series Workshop offer participants the tools they need to begin implementing one-piece flow and cell design into their plant. Learn how to transform your current production to one continuous flow, see how to make processing time drop from hours to minutes and lead times go from weeks to hours.

The experience starts in the classroom, where participants learn methods for analyzing and correcting problems on the shopfloor. Understand how to identify waste, the difference between takt and cycle time, and how to apply the principles of standard work to the newly designed work areas. But the course isn´t just about theory and numbers; it´s about producing real change in real time. We take participants to a host facility where, in teams, they get to apply their new skills to the work environment—get their hands dirty, move machines, set up manufacturing cells, and design new process flows. And they will practice working successfully as part of a team. At the end of the program each team will report results to the group.

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Module2: Kanban Design and Management
Eliminate product shortages and production control complexity, and regain control of inventory—experience firsthand the benefits of pull-based production rather than push.

The Kanban Master Series Workshop offers a thorough understanding of the methodology of kanban and how it can stabilize production operations. Participants will explore how kanban is integrated into your value stream, as well as how it interrelates and integrates with other Lean tools like demand management, supermarkets, product families, continuous flow, cellular manufacturing and Lean scheduling concepts. Participants will gain an understanding of the design and functionality of a kanban board and card system and the kanban equation—the formula necessary to determine the number of kanban needed to establish a Lean inventory level.

The training presents kanban as an alternative to traditional computerbased production control techniques and creates a high degree of flexibility in being able to respond to changes in customer demand. Upon completion of the formal classroom-training portion of the event, participants will be divided into teams. Working alongside associates from the host facility, participants will be closely facilitated through the process of designing and then implementing a fully functional kanban system in designated pilot areas. At the end of the program each team will report results to the group.

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Module3: Lean Office and Implementation
consider this: 75% of your organization's opportunity for waste elimination can be found in areas other than manufacturing. Combine this fact with research that suggests white collar knowledge workers are only 40% to 60% productive and the possibilities for improvement are enormous. When you consider that payroll can be a multiplier of 10 times earnings, think what it would mean to raise organizational productivity by just 7%!

There’s been a great deal of attention implementing Lean in manufacturing… now it’s time to look at the entire enterprise and implement Lean in non-manufacturing as well.

During this 5 day hands-on event, you will learn how to apply the principles of waste elimination to administrative areas in a real-time working office environment. The Lean Office – Transactional Master Series provides both classroom and hands-on work site activities where participants learn the principles and improvement processes to create and sustain a Lean Transactional environment.


The Master Series Event Includes:

During the classroom training participants explore the transactional work place, a knowledge based, system focused environment, and learn to identify the waste elimination opportunities. Participants are introduced to a Lean Improvement Process that will focus them as they diagnosis the office and formulate improvement plans.

Then, working in teams along side associates from the host facility, participants will work to transform an actual real-time current state situation to future state in one of the pre-designated pilot areas. On Friday morning each team will do a report-out. The report will story-board the team’s activities, from current state and future state maps, opportunities identified, tool applications, improvements implemented and results achieved.

If you want to spread Lean throughout your non-manufacturing environment, and along-the-way create the culture necessary to sustain the effort, then you must attend this intensive 5Day Lean Office Transactional Master Series event.

Module4: TPM and Implementation
Reduce your equipment-related costs, increase throughput and reduce waste.

The Maintenance Miracle Master Series Workshop is a team-based approach to maintenance activities and part of a total productive maintenance (TPM) program. Based on Autonomous Maintenance (AM), the goal is to prepare operators to do some equipment care independent of the maintenance staff. The program is a partnership between operators, technicians, engineers and managers in the running and maintaining of equipment.

This kaizen event is a hands-on training workshop on the proven methodology for the successful implementation of an AM effort. Learn the steps necessary to involve operators in maintaining their own equipment through daily inspections, lubrications, parts replacement, simple repairs, detecting abnormalities and precision checks. The result is a restoration of equipment to its ideal state, establishment of basic conditions for maintaining it, and preventing equipment deterioration. Properly implemented, AM eliminates the causes of 40%-60% of unplanned downtime, freeing up skilled trades for more specialized activities.

Participants will learn how AM is developed to support Lean manufacturing and how it maximizes equipment effectiveness. At the host facility, in teams, participants get to apply the methods learned to the work environment. At the end of the program each team will report results to the group.

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Module5: 5S and Visual Control Implementation
Eliminate waste, reduce costs, improve safety, shorten search time, raise morale and pride.

The Visual Master Series Workshop is the essential foundation for successful Lean implementation. Participants will learn the principles of a visual control system and how to put those principles into action on the shopfloor.

On the first day, participate in an exercise that teaches the principles of a visual management system. In this simulated work environment, participants assume the role of a plant manager, customer, quality inspector, material handler, supervisor, and production employee, and learn the basics of 5S, visual displays, visual metrics and visual controls.

Moving to the shopfloor on the second and third days, participants begin to implement what they have learned. Working in teams with associates from the host facility, participants begin to implement 5S and get the workplace organized. Participants will also utilize other visual management methods to improve communication, quality and adherence to standards. At the end of the program each team will report results to the group.

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