LEAN MASTER Certification Program -- 2012-2013

OVERVIEW Lean is a systematic approach to identifying and eliminating waste (muda) in all enterprise processes by enabling value to flow, at the pull of the customer, in pursuit of perfection. A Lean Enterprise establishes a culture that empowers people to strategically improve processes. The MRC LEAN MASTER Certification program was created to assist companies with the challenge of implementing and maintaining improvements in Lean Manufacturing. This proven methodology includes a series of training modules designed to provide targeted technical competencies in Lean Manufacturing.

LEAN Certification Program - Kickoff Breakfast (September 13, 2012 – 7:30 am – 8:15 am) at MRC

During our first meeting, participants learn about the upcoming program schedule and certification requirements. Participants are encouraged to consider hosting one of several “train & do” workshops to see the benefits of Lean at their facility. This is also the first of many great networking opportunities!

LEAN 101 (September 13, 2012 – 8:30 am – 4:30 pm) at MRC In this workshop you will be introduced to the Lean philosophy. Participants gain an understanding of value adding and non-value adding activities, as well as, methods of identifying improvement opportunities. In addition, Lean tools are presented for the elimination of process waste. This workshop includes a live simulation where participants are assigned jobs, like material handler or assembler, and experience a Lean transformation through hands on activities. You will move from the presentation format to the simulated shop floor during this workshop to apply the concepts that you learn. You will also discuss the use of visual methods to measure production system performance. Presenter: Mike Withka

PROBLEM SOLVING & STANDARD WORK (September 25 – 27, 2012 - 8:30 am – 4:30 pm) Location TBD

This three-day training explores the importance of problem solving, the A3 Problem solving Methodology and role of standard work in creating stability. Day 1 focuses on the corner-stone role of problem solving within Lean environments and the relationships between purpose, process and people. Toyota’s eight step (A3) problem solving methodology using PDCA (plan-do-check-act) principles is presented as a systematic approach to real time problem solving. Day 2 is spent applying the A3 problem methodology on real enterprise processes. Participants will work in teams on pre-selected problems at a host facility. Day 3 will be spent learning how to establish standards and develop standard work. Teams will have an opportunity to create standard work as a means of sustaining problem solving countermeasures at the host facility. This class is taught by nationally renowned, former Toyota Manager, Presenter: TRACEY RICHARDSON.

Benefits of LEAN

PARTICIPANTS Learn to become a catalyst for change Learn how to create and sustain change Learn how to identify & eliminate waste Increase your value as a LEAN Leader Receive advanced training ______________________________________

COMPANY

Improve all areas of your business Increase profits and growth Gain internal and external support Develop a market leader perspective Maintain more satisfied customers

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TEAM FACILITATION (October 10, 2012 – 8:30 am – 4:30 pm) at MRC

In this workshop, each participant’s method of processing information will be analyzed through an IOPT survey. The IOPT survey identifies individuals’ inclined method of processing information and subsequent behavioral patterns when acting on information. Participants then learn how to organize effective team meetings and improvement initiatives by considering individuals IOPT profiles. Presenter: Mike Witha 5S: WORKPLACE ORGANIZATION “TRAIN & DO” (October 24 -26, 2012 - 8:30 am – 4:30 pm) at MRC This three-day event includes one of in classroom training at MRC which then follows with two days of “doing” at a host company. Learn to reduce waste through a systematic application of the 5S System – Sort, Set in Order, Shine, Standardize, and Sustain. This workshop teaches the basic 5S techniques presented through a simulation that resembles an actual shop floor, using a production line with assembly areas, tools, inventory, and workers. A two day hands-on training at a host facility will follow the first day classroom session. Presenter: Mike Withka

SETUP REDUCTION TRAIN AND DO (November 7, 2012 – 8:30 am – 4:30 pm) Location TBD Setup Reduction is a Lean tool that improves equipment available by reducing or eliminating sources of equipment downtime. This training is based on the pioneering work of Dr. Shigeo Shingo and his SMED |System of Setup Reduction. A hands-on simulation is used to demonstrate a “traditional” setup. Participants then apply techniques learned in the classroom to observe, document, analyze and improve the simulated setup. Participants will also apply these techniques to observe, document, analyze and suggest improvements for an actual setup from a manufacturing company. Presenter: Mike Withka TOTAL PRODUCTIVE MAINTENANCE (TPM) (December 11 – 12, 2012 – 8:30 am – 4:30 pm) Location TBD The goal of TPM is to maximize your Overall Equipment Effectiveness (OEE), reduce equipment downtime to zero, improve quality, increase capacity, and maximize the productivity of your equipment. TPM also fosters improvements in Safety, Quality, Delivery, Cost and Creativity through employee participation. Learn to approach zero equipment stoppages in 4 phases: stabilize failure intervals, improve equipment productivity, maintenance excellence and predict equipment life. This course is held at a host facility and is taught by JOHN KRAVONTKA, President of Fuss & O’Neill Manufacturing Solutions, LLC. John is nationally recognized and is a certified maintenance and reliability professional and a continuous improvement advisor with more than 38 years of troubleshooting and retrofit experience with many types of equipment. Presenter: John Kravontka CELLULAR MANUFACTURING (January 9, 2013 - 8:30 am – 4:30 pm) at MRC Learn how linking and balancing process steps can reduce process lead times by as much as 95%, work-in-process by 90%, and floor space by 50-75% while increasing productivity by 40% or more. This hands-on course teaches how to link and balance manufacturing operations to reduce lead times, minimize work-in-process, optimize floor space usage and improve productivity. The instructor leads the class through the 5-step process for designing and implementing work cells using a live simulation. This process applies to both assembly and machine applications. Presenter: Mike Withka PULL SYSTEMS/KANBAN (January 23, 2013 – 8:30 am– 4:30 pm) at MRC

“Flow where you can, pull where you can’t”. This course teaches a method of controlling the flow of materials and information through the factory based on using an “image” of customer demand. Pull Systems control production resources by initiating activity only in response to actual consumption rather than through forecasting. Implementing Pull Systems can help you eliminate wastes associated with handling, storing and rework, as well as improve on-time delivery performance. This workshop shows participants how to create a pull system strategy to support Lean transformation in both repetitive and job shop production environments. Super market locations, inventory sizes, order points and visual inventory management will be discussed. In addition, a financial tool is presented as a means to capture the economic impact of using pull systems to manage inventories. Don Guild, President of Synchronous Management, will conduct the pull systems workshop. Presenter: Don Guild

Page 3 of 4 ________________________________________________________________________________________ VALUE STREAM MAPPING (VSM) and LEAN Accounting (February 12-13, 2013 - 8:30 am – 4:30 pm) Location TBD

This two-day course demonstrates techniques for creating value stream maps. You will learn how to create a product/process matrix to identify a product family, document the condition of the value stream through a current state map, establish an improvement vision for the product family by generating a future state map and develop an implementation plan to realize the future state map. Participants will apply methods of value stream mapping to classroom case studies. Lean Accounting is a set of financial tools designed to assist Lean practitioners in evaluating the financial performance of a value stream. Participants learn to re-assign costs to develop a clear picture to help prioritize improvement activities that impact the financial performance. Lean accounting tools will be applied to a classroom case study to enhance learning. Presenter: Mike Withka

LEAN CULTURE (MARCH 25-27, 2013, 8:30 am – 4:30 pm) Location TBD This course will demonstrate how to connect and develop “Product” and “People” Value Streams that will help you accelerate your Lean implementation, by setting a foundation for a sustainable Lean culture. This three-day program teaches what you and your team will need to change in your current role to successfully lead a Lean Transformation. You will understand how to create management systems and infrastructure that make problems visible and engage team members at all levels in rigorous problem solving and continuous improvement processes. You will complete an assessment of your organization revealing gaps in terms of its leadership, technical and human systems that need to be addressed in order to build a Lean culture. You will develop a clear action plan to address the prioritized gaps utilizing Hoshin planning, and Lean Management Systems. Nationally renowned, former Toyota Manager, MIKE HOSEUS will be presenter and instructor at this event. Presenter: Mike Hoseus

ROUND TABLE AND PLANT TOUR (April 9, 2013 - 1/2 day - 8:30 am – 12:30 pm) Location TBD In support or the classroom and practical content, Lean Master Certification students will receive a reading assignment. At the

round table, teams will collaborate to present material from the reading. Participants will also have an opportunity to tour a nearby manufacturing facility to see Lean best-practices in use. After the tour, the host company will receive feedback from the attendees to help them along on their Lean journey. Facilitator: Mike Withka

FINAL EXAM (April 23, 2013 - 8:30 am – 12:30 pm) at MRC All students seeking certification must pass an examination to test their understanding of the Lean Body of Knowledge. With additional reading, MRC Lean Master Certification students may wish to take SME’s Bronze Level Certification Exam. SME examination preparation and examination proctoring is conducted by a certified SME instructor and is available through the MRC for an additional fee.

PROJECT SUBMISSION (JULY 31, 2013) All Lean Master Certification candidates must submit their final reports by July 31, 2013 to qualify for MRC certification. The MRC Lean Master Certification project demonstrates candidates’ ability to apply Lean techniques to an improvement project within their respective organizations. The project format and requirements are designed to prepare candidates for SME Bronze Level Certification.

Testimony: “When I started this process I was not only new to the concept of Lean, I was new to manufacturing. The course was structured in a way that had me evolving quickly. Once I was exposed and had accepted some of the principles of Lean, there was no turning back. I was amazed at how much “low hanging fruit” there was and how I could easily apply the tools of lean during my daily activities at work. I started getting even more effective the closer I got to being certified. I’m extremely grateful for the opportunity to go through this process with some great people, I learned so much in such a short time that I can use every day.” ………. J. Michael

Weaver, Manufacturing Supervisor, Precision Medical Products, Inc.

Instructors include nationally recognized LEAN experts Content prepares you for the SME Bronze Exam Ability to network with other Lean practitioners Gain first hand exposure to companies that are well into their Lean transformation Train and Do format – hands-on experience and learning Consistent LEAN mentor throughout the program Hands on workshops

COST Per Person

$4495 ($3995/3 or more)

$7,500 Value if Purchased Separately

Enroll Now

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Topic Where Dates Times

Kickoff Breakfast Lean Certification Program MRC September 13th 7:30 - 8:15

Lean 101 MRC September 13th 8:30 - 4:30

Standard Work and Problem Solving MRC

Sept. 25th –Sept. 27th 8:30 - 4:30

Team Facilitation MRC October 10th 8:30 – 4:30

5S Train and Do MRC Oct. 24th – Oct.

26th 8:30 – 4:30

Setup Reduction Train and Do MRC November 14th 8:30 - 4:30

TPM (Total Productive Maintenance) MRC

Dec. 11th – Dec. 12th 8:30 - 4:30

Cellular Manufacturing MRC January 9th 8:30 - 4:30

Pull Systems / Kanban MRC January 23th 8:30 - 4:30

Value Stream Mapping and Lean Accounting MRC

Feb. 12th – Feb. 13th 8:30 - 4:30

Lean Culture MRC March 25th – March 27th 8:30 – 4:40

Round Table or Plant Tour TBD April 9th 8:30 - 12:30

Final Examination MRC April 23rd 8:30 – 12:30

Quick View

2012-2013 LEAN Certification Course Schedule

(Continental Breakfast & Lunch Provided)

To Register & Pay Online

Questions?

Contact: Pat Felise, Lean Coordinator Phone: 610-758-6069 * Fax: 610-758-4716 * Email: pat.felise@mrcpa.org

Enroll Now