Lean Expert | Certification Program

Lean Problem Solving: solving problems effectively and efficiently

• Defining a problem
• The Steps of Problem Solving
• The problem setting:
  • Description
  • Pareto and stratification
  • Goal setting and indicators
• The methodology of analysis: the PDCA
• Root cause analysis through survey instruments (6M to 5 Why)
• Proper definition of targets and objectives
• The consolidation of achievements: standardization and training through SOP (Standard Operating Procedure) and OPL (One Point Lesson)

Managing a project: delving into the techniques and tools of managing resources in a project efficiently

•  Project phases and the 5 Lean principles
• Lean PUSH VS PULL Approach
• Definition of project objectives
• Sizing Resources: rules and principles
• Project Charter: Project form structure and filling out
• Visual planning tools short, medium and long term
• WBS (Work Breakdown Structure)
• Stage & Gate

The concept of flow and its balance

• Methods and tools for materials management in production areas (Synchro logic and Kit system; Kanban logic and Supermarket sizing with Pull System)
• Where and why the flow does not flow: Push, Pull, Takt time, One Piece flow

Session simulative: real assembly of products in island configuration and calculation of indicators

• How to balance production flows
• The daily improvement of production performance: the Flash Meeting
• Application of improvements and rebalancing of assembly flow

Session simulative: Mounting of products in configuration line With assistance from digital systems

OEE and Shop Floor Management: how to improve through production data

• Introduction on the principles of TPM
• The OEE indicator and how to measure it
• Machine and plant production losses, their classification and aggregation

Session simulative: work shift simulation on plant, collection of losses and OEE indicator calculation

• Training on the use of Shop Floor Management tools and daily meeting simulation for loss attack
• Proposed improvement actions to resolve top5 leaks and actual implementation
• Digital capture of machine status, with recording of times and types of losses

Session simulative: Application of improvement ideas and automatic OEE recalculation with data collected and reclassified into via digital.

5S and Visual Management: lo Visual standard as a basic tool for discipline and improvement

• Introduction to the 5S methodology
• The indicators of workplace efficiency
• How to recognize workplace inefficiency and propose improvements

Session simulative: identification of waste and inefficiencies of the workstation on assembly benches

• Application of 5S, one S at a time, to understand achievable improvements

Session simulative: Implementation of proposed improvements and calculation of indicators

SMED: production change as an opportunity for improvement

• Introduction on SMED objectives and methodology to reduce and simplify production changeover time
• Production change matrix training session: how to choose a representative production change

Simulative session: Execution of change Movie production on a real machine with anomaly collection

• Training on SMED principles and tools, chronotechnical analysis of setup sequence
• Proposing ideas for improvement and streamlining change activities

Simulative session: Testing the new shifting procedure on a real machine and comparing the results obtained

Autonomous Maintenance (AM): clean and Inspect to increase efficiency

• Introduction on the objectives and key concepts of Autonomous Maintenance

Session simulative: Conduction of a production facility and identification of the lack of basic conditions

• Communicate in an organized way to solve problems (the Visual tag) even after the construction phase
• Attacking leakage due to lack of basic conditions of a plant and implementing proposed solutions
• Creating operational standards based on Visual Management and ensuring maintenance and improvement through operational procedures and tools

Session simulative: Implementation standard start/end of work to ensure work efficiency

Value Stream Mapping: Identifying and mapping as-is and to-be value

Simulative session: group exercise on value stream mapping

• The Lean World Class® Approach.
• Provide a clear and comprehensive view of flows for a product family
• Highlight the connection between the flow of materials and the flow of information
• Calculate the Flow Index
• Identifying waste: Not Value Added Activities (NVAA or "muda")
• Introduction to the use of Lean methodology and its Lean tools (Kanban, 5S, JIT, TPM, SMED, ...)
• Creating a Future State Map, reducing existing waste
• Checking the improvements made by applying the methods learned in the previous days

Project Work

• Support for the selection of Project Work to be carried out independently in the company and completion of the relevant project A3