Lean Blackbelt Certification
Lean Blackbelt Certification Workshop Series
1. Lean Leadership Seminar (1 Day)
2. Lean Champion Training (3 Days)
3. Lean Project Management, OEE, TPM & SMED
(4 Days)
4. Achieving Continuous Flow (4 Days)
5. Utilizing Supermarket-Pull with Kanbans (4 Days)
6. Implementing Five S’s for Workplace Organization & Visual Management for
Continual Process Improvement (4 Days)
Total: 20 days
___________________________________________________________________________
Lean Leadership Seminar (1 Day)
Program Content
This one-day program will help you to understand how your company can use Lean technologies to
achieve significant improvements in quality, cost and delivery performance. This seminar offers an
overview of the tools, strategies and improvement objectives of Lean. Seminar participants will
learn how to use Value Stream Mapping and linked scorecards to plan and deploy Lean
improvement projects. Participants will learn how to take Lean from concept to continuous
improvement.
Who Should Attend
This program is intended for Senior Management and Operations Managers who have been
selected to play a leadership role in the deployment of Lean in your company. This program is
limited to a maximum of 12 participants.
Prerequisites
None.
Program Goals
To develop understanding of the improvements that can be achieved from adopting an integrated
approach to Lean and the roles and responsibilities of Company leaders in planning, organizing
and directing Lean improvement projects. This seminar also develops a basic level of
understanding of the improvement philosophy, strategies and tools of Lean. The primary goal of
this workshop is to understand the process for identifying and prioritizing improvement
opportunities that can be addressed through Lean projects.
Program Materials
Each participant will receive a manual of all course materials plus a computer disc of forms, charts,
files and reports needed to plan, organize and improve process performance with Lean
Technology.
Program Outline
• Introduction to Lean Manufacturing
• The Philosophy, Strategies and Tools of Lean
• Lean Demonstration
• The Operational and Financial Benefits of Lean
• Introduction to Linked Scorecards
• Introduction to Value Stream Mapping
• Drawing Current State Value Stream Maps
• Designing Future State Value Streams
• Leading the Transformation from Current State to Future State
• The Lean Organization
• Managing Lean Projects
• Executive Reports and Review
___________________________________________________________________________
Lean Champion Training (3 days)
Workshop Content
This three-day workshop develops the knowledge and skills for planning and leading your
company’s Lean Improvement Process. This workshop introduces Value Stream Mapping to
measure and define the process improvement opportunities. Workshop participants will analyze
and document the current state value stream for one of your existing product families. They will then
create future state value stream maps that identify and quantify the opportunities for improving
process performance through the deployment of Lean technologies. Ultimately, the workshop
participants will produce project logs and project plans for achieving those improvements. This
workshop also introduces the concept and practice of Linked Scorecards. Champions will create
product, process and project scorecards to link each improvement project to bottom-line results.
Who Should Attend
This workshop is intended for those responsible for leading and managing the Lean improvement
projects that will follow. The training is team-based training. Each team should include the
Process Owner (The Champion) and the Lean Black Belt Candidates (up to 4 per team). This
workshop is limited to three process improvement teams.
Prerequisites
None.
Workshop Materials
Each participant will receive a Lean Project Planning Manual with all course materials; and, a CD
ROM with files, reporting forms, charts and graphs needed to plan, organize and deploy Lean.
Workshop Goals
To develop understanding of the Lean & Six Sigma improvement philosophy, process and tools.
To develop knowledge and skills for creating current and future state value stream maps; and, for
each team to create a current state map, future state map and a Lean & Six Sigma
implementation plan for one of your product families.
Workshop Outline
• Introduction to Lean
• Introduction to Value Stream Mapping
• Drawing Current State Maps
• Measuring the Current Performance – Process & Financial Data Collection
• Analyzing the Current State using the Lean & Six Sigma Planning Process
• Drawing Future State Maps
• Gap Analysis – Future State versus Current State Performance
• Lean Six Sigma Project Planning
• Management Reports & Management Review of Project Plans
___________________________________________________________________________
Lean Project Management, OEE, TPM & SMED (4 Days)
Workshop Content
This program develops knowledge and skills for planning, organizing and leading Lean
Improvement Project Teams. This workshop also offers instruction and practice in measuring and
improving overall equipment effectiveness (OEE). Participants will learn how to improve OEE by
leading project teams to implement a Total Productive Maintenance System (TPM). Participants
will also learn how to reduce setup and changeover times and improve quality yields through
application of SMED (Single Minute Exchange of Dies). This workshop will provide instruction and
guided practice in the application of SMED for streamlining equipment changeover processes.
Participants will also determine the potential cost savings and increased productive capacity
resulting from improved OEE.
Who Should Attend
This workshop is intended for Champions and Lean Black Belt Candidates responsible for
improving quality and productivity in manufacturing operations. This training is team-based
training. The team should include the Process Champion and up to four Lean Black Belt
Candidates. There is a limit of 3 teams per session.
Prerequisites
Participants must have completed the Lean Champion Training.
Workshop Materials
Each participant will receive a Manual with all course materials. Each participant will also receive
a CD ROM with programs, charts, graphs, tables and reports necessary to plan, organize and lead
Lean & Improvement Project Teams.
Workshop Goals
To develop knowledge and skills for leading Lean & Project Teams. To develop the knowledge
and ability to measure and manage OEE. To develop the ability to lead project teams to achieve
quick changeovers through application of SMED methodology. To develop knowledge for leading
project teams to plan and implement a system of Total Productive Maintenance.
Workshop Outline
• Introduction to Project Team Leadership
• Defining Team Roles, Responsibilities and Reporting Structures
• Introduction to OEE
• Calculating OEE
• The Six Big Losses That Effect OEE
• Introduction to TPM
• Developing and deploying TPM
• Introduction to SMED for Quick Changeovers
• Developing and Deploying Quick Changeover Methods
• Project Reports
___________________________________________________________________________
Achieving Continuous Flow (4 Days)
Workshop Content
This four-day workshop develops knowledge and skills for implementing continuous flow in
manufacturing and assembly processes. Participants will learn: how to conduct work element
analysis, how to calculate takt times, how to create operator balance charts, how to evaluate and
improve equipment layout and material presentation; and, how to plan and implement standard
work methods to reduce the labor, material and facilities costs in manufacturing and assembly
operations.
Who Should Attend
This workshop is intended for Lean Black Belts responsible for planning, organizing and managing
continuous improvement of manufacturing and assembly processes. This training is team-based
training. Each team should include the Champion plus up to four Lean Black Belt Candidates. A
maximum of three teams is allowed per session.
Prerequisites
Participants must have completed Champion Training and all previous Lean Black Belt
Workshops prior to enrolling in this program.
Workshop Materials
Each participant will receive a Manual with all course materials included. They will also receive a
CD ROM of charts, graphs, reports, files and forms necessary to plan, organize and deploy Lean.
Workshop Goals
This workshop is intended to develop knowledge of the philosophy, process and tools of
continuous flow processing. This workshop will also provide participants with the opportunity to
practice the application of continuous flow processing in a live manufacturing or assembly
process. This workshop will also help participants to identify and quantify the cost savings from
continuous flow processing projects.
Workshop Outline
• Introduction to Continuous Flow Processing
• Conducting the Process Analysis – Current State Performance Data
• Constructing Operator Balance Charts
• Analyzing the Current Layout and Material Flow
• Considering the Role of Automation
• Designing the Future State Layout and Material Flow
• Determining the Cost Savings from Continuous Flow Processing
• Planning & Deploying the Future State Cell Design
• Developing Standard Work Methods and Charts
• Management Reports
___________________________________________________________________________
Utilizing Supermarket-Pull with Kanbans (4 Days)
Workshop Content
This four-day workshop develops knowledge and skills for developing pull-scheduling systems to
be used where continuous flow is not yet possible. Participants will learn how to determine
appropriate levels of inventory needed to maintain production schedules with minimum waste.
Participants will learn how to develop and deploy Kanbans for real-time shop floor production
scheduling and inventory management. Participants will learn how to determine the cost savings
from supermarket-pull scheduling.
Who Should Attend
This workshop is intended for Lean Champions and Black Belt Candidates responsible for
planning, organizing and completing Lean Projects. This training is team-based training. Each
team should include the Lean Champion and up to four Lean Black Belt Candidates. Maximum of
3 teams per session allowed.
Prerequisites
Participants must have completed Champion Training and all previous Lean Workshops prior to
enrolling in this program.
Workshop Materials
Each participant will receive a Supermarket-Pull Scheduling Manual that contains all course
materials. Each participant will also receive a CD ROM with files, reports, forms and charts used
to plan, organize and deploy Lean.
Workshop Goals
This workshop is intended to develop understanding of supermarkets, pull scheduling and
Kanbans. To develop knowledge and skills for deploying supermarkets & Kanbans to control
inventory levels and schedule the production and delivery of raw materials, work-in-process and
finished goods inventories. To practice the deployment of supermarket pull systems using
Kanbans in a live manufacturing, assembly or purchasing process. To identify and quantify the cost
savings from the improved inventory control and production scheduling performance resulting from
the use of pull scheduling.
Workshop Outline
• Introduction to Pull Systems
• Introduction to Supermarkets
• Introduction to Kanbans
• Introduction to Heijunka (leveling)
• Determining Appropriate Inventory Levels
• Designing Supermarkets
• Creating Kanbans for Production Scheduling & Inventory Control
• Determining Cost Savings from the Supermarket Pull System
• Management and Continuous Improvement of the Supermarket Pull System
• Management Reports & Management Review
___________________________________________________________________________
Implementing Five S’s for Workplace Organization & Visual
Management for Continual Process Improvement (4 Days)
Workshop Content
This four-day workshop develops the knowledge and skills for planning, organizing and
implementing the Five S Method for Workplace Organization. Workshop participants will also learn
how the Five S process fits into a total system of Visual Management. Workshop participants will
receive instruction and guided practice in planning and deploying visual management systems for
the continual improvement of process quality, productivity, housekeeping, safety and employee
development. Participants will learn how to create standards for each type of performance and to
use the concept and practice of Visual Controls to integrate those standards into daily practice.
Who Should Attend
This workshop is intended for Champions and Black Belt Candidates responsible for
implementing and managing Lean improvement projects.
Prerequisites
This is the final workshop in the Lean Training System. Participants must have completed
Champion Training and all previous Lean Workshops prior to enrolling in this program.
Workshop Materials
Each workshop participant will receive a Manual with all course materials. Each participant will
also receive a CD ROM with all necessary files, reports, forms, charts, graphs and tables
necessary to plan, organize and lead Lean Project Teams.
Workshop Goals
This workshop develops understanding of the philosophy and process for achieving workplace
organization through the Five S Method. Participants will conduct a Five S Campaign to clean and
organize one or more locations in your plant/office operations. Participants will also utilize Visual
Management Methods to Control process performance in order to “hold the gains” achieved.
Workshop Outline
• Introduction to the Five S Method
• Sort - identify and sort items by frequency of use
• Store – prepare and label storage locations for all items
• Shine – conduct a campaign to repair, clean and shine the work area
• Sustain – implement regular 5 S audits to sustain the improvements
• Spread – apply the lessons learned to other plant/office areas
• Introduction to Visual Management
• How to write Performance Standards
• Making Performance Standards Visual
• Preparing and presenting Management Reports
Lean Blackbelt Certification Workshop Series
1. Lean Leadership Seminar (1 Day)
2. Lean Champion Training (3 Days)
3. Lean Project Management, OEE, TPM & SMED
(4 Days)
4. Achieving Continuous Flow (4 Days)
5. Utilizing Supermarket-Pull with Kanbans (4 Days)
6. Implementing Five S’s for Workplace Organization & Visual Management for
Continual Process Improvement (4 Days)
Total: 20 days
___________________________________________________________________________
Lean Leadership Seminar (1 Day)
Program Content
This one-day program will help you to understand how your company can use Lean technologies to
achieve significant improvements in quality, cost and delivery performance. This seminar offers an
overview of the tools, strategies and improvement objectives of Lean. Seminar participants will
learn how to use Value Stream Mapping and linked scorecards to plan and deploy Lean
improvement projects. Participants will learn how to take Lean from concept to continuous
improvement.
Who Should Attend
This program is intended for Senior Management and Operations Managers who have been
selected to play a leadership role in the deployment of Lean in your company. This program is
limited to a maximum of 12 participants.
Prerequisites
None.
Program Goals
To develop understanding of the improvements that can be achieved from adopting an integrated
approach to Lean and the roles and responsibilities of Company leaders in planning, organizing
and directing Lean improvement projects. This seminar also develops a basic level of
understanding of the improvement philosophy, strategies and tools of Lean. The primary goal of
this workshop is to understand the process for identifying and prioritizing improvement
opportunities that can be addressed through Lean projects.
Program Materials
Each participant will receive a manual of all course materials plus a computer disc of forms, charts,
files and reports needed to plan, organize and improve process performance with Lean
Technology.
Program Outline
• Introduction to Lean Manufacturing
• The Philosophy, Strategies and Tools of Lean
• Lean Demonstration
• The Operational and Financial Benefits of Lean
• Introduction to Linked Scorecards
• Introduction to Value Stream Mapping
• Drawing Current State Value Stream Maps
• Designing Future State Value Streams
• Leading the Transformation from Current State to Future State
• The Lean Organization
• Managing Lean Projects
• Executive Reports and Review
___________________________________________________________________________
Lean Champion Training (3 days)
Workshop Content
This three-day workshop develops the knowledge and skills for planning and leading your
company’s Lean Improvement Process. This workshop introduces Value Stream Mapping to
measure and define the process improvement opportunities. Workshop participants will analyze
and document the current state value stream for one of your existing product families. They will then
create future state value stream maps that identify and quantify the opportunities for improving
process performance through the deployment of Lean technologies. Ultimately, the workshop
participants will produce project logs and project plans for achieving those improvements. This
workshop also introduces the concept and practice of Linked Scorecards. Champions will create
product, process and project scorecards to link each improvement project to bottom-line results.
Who Should Attend
This workshop is intended for those responsible for leading and managing the Lean improvement
projects that will follow. The training is team-based training. Each team should include the
Process Owner (The Champion) and the Lean Black Belt Candidates (up to 4 per team). This
workshop is limited to three process improvement teams.
Prerequisites
None.
Workshop Materials
Each participant will receive a Lean Project Planning Manual with all course materials; and, a CD
ROM with files, reporting forms, charts and graphs needed to plan, organize and deploy Lean.
Workshop Goals
To develop understanding of the Lean & Six Sigma improvement philosophy, process and tools.
To develop knowledge and skills for creating current and future state value stream maps; and, for
each team to create a current state map, future state map and a Lean & Six Sigma
implementation plan for one of your product families.
Workshop Outline
• Introduction to Lean
• Introduction to Value Stream Mapping
• Drawing Current State Maps
• Measuring the Current Performance – Process & Financial Data Collection
• Analyzing the Current State using the Lean & Six Sigma Planning Process
• Drawing Future State Maps
• Gap Analysis – Future State versus Current State Performance
• Lean Six Sigma Project Planning
• Management Reports & Management Review of Project Plans
___________________________________________________________________________
Lean Project Management, OEE, TPM & SMED (4 Days)
Workshop Content
This program develops knowledge and skills for planning, organizing and leading Lean
Improvement Project Teams. This workshop also offers instruction and practice in measuring and
improving overall equipment effectiveness (OEE). Participants will learn how to improve OEE by
leading project teams to implement a Total Productive Maintenance System (TPM). Participants
will also learn how to reduce setup and changeover times and improve quality yields through
application of SMED (Single Minute Exchange of Dies). This workshop will provide instruction and
guided practice in the application of SMED for streamlining equipment changeover processes.
Participants will also determine the potential cost savings and increased productive capacity
resulting from improved OEE.
Who Should Attend
This workshop is intended for Champions and Lean Black Belt Candidates responsible for
improving quality and productivity in manufacturing operations. This training is team-based
training. The team should include the Process Champion and up to four Lean Black Belt
Candidates. There is a limit of 3 teams per session.
Prerequisites
Participants must have completed the Lean Champion Training.
Workshop Materials
Each participant will receive a Manual with all course materials. Each participant will also receive
a CD ROM with programs, charts, graphs, tables and reports necessary to plan, organize and lead
Lean & Improvement Project Teams.
Workshop Goals
To develop knowledge and skills for leading Lean & Project Teams. To develop the knowledge
and ability to measure and manage OEE. To develop the ability to lead project teams to achieve
quick changeovers through application of SMED methodology. To develop knowledge for leading
project teams to plan and implement a system of Total Productive Maintenance.
Workshop Outline
• Introduction to Project Team Leadership
• Defining Team Roles, Responsibilities and Reporting Structures
• Introduction to OEE
• Calculating OEE
• The Six Big Losses That Effect OEE
• Introduction to TPM
• Developing and deploying TPM
• Introduction to SMED for Quick Changeovers
• Developing and Deploying Quick Changeover Methods
• Project Reports
___________________________________________________________________________
Achieving Continuous Flow (4 Days)
Workshop Content
This four-day workshop develops knowledge and skills for implementing continuous flow in
manufacturing and assembly processes. Participants will learn: how to conduct work element
analysis, how to calculate takt times, how to create operator balance charts, how to evaluate and
improve equipment layout and material presentation; and, how to plan and implement standard
work methods to reduce the labor, material and facilities costs in manufacturing and assembly
operations.
Who Should Attend
This workshop is intended for Lean Black Belts responsible for planning, organizing and managing
continuous improvement of manufacturing and assembly processes. This training is team-based
training. Each team should include the Champion plus up to four Lean Black Belt Candidates. A
maximum of three teams is allowed per session.
Prerequisites
Participants must have completed Champion Training and all previous Lean Black Belt
Workshops prior to enrolling in this program.
Workshop Materials
Each participant will receive a Manual with all course materials included. They will also receive a
CD ROM of charts, graphs, reports, files and forms necessary to plan, organize and deploy Lean.
Workshop Goals
This workshop is intended to develop knowledge of the philosophy, process and tools of
continuous flow processing. This workshop will also provide participants with the opportunity to
practice the application of continuous flow processing in a live manufacturing or assembly
process. This workshop will also help participants to identify and quantify the cost savings from
continuous flow processing projects.
Workshop Outline
• Introduction to Continuous Flow Processing
• Conducting the Process Analysis – Current State Performance Data
• Constructing Operator Balance Charts
• Analyzing the Current Layout and Material Flow
• Considering the Role of Automation
• Designing the Future State Layout and Material Flow
• Determining the Cost Savings from Continuous Flow Processing
• Planning & Deploying the Future State Cell Design
• Developing Standard Work Methods and Charts
• Management Reports
___________________________________________________________________________
Utilizing Supermarket-Pull with Kanbans (4 Days)
Workshop Content
This four-day workshop develops knowledge and skills for developing pull-scheduling systems to
be used where continuous flow is not yet possible. Participants will learn how to determine
appropriate levels of inventory needed to maintain production schedules with minimum waste.
Participants will learn how to develop and deploy Kanbans for real-time shop floor production
scheduling and inventory management. Participants will learn how to determine the cost savings
from supermarket-pull scheduling.
Who Should Attend
This workshop is intended for Lean Champions and Black Belt Candidates responsible for
planning, organizing and completing Lean Projects. This training is team-based training. Each
team should include the Lean Champion and up to four Lean Black Belt Candidates. Maximum of
3 teams per session allowed.
Prerequisites
Participants must have completed Champion Training and all previous Lean Workshops prior to
enrolling in this program.
Workshop Materials
Each participant will receive a Supermarket-Pull Scheduling Manual that contains all course
materials. Each participant will also receive a CD ROM with files, reports, forms and charts used
to plan, organize and deploy Lean.
Workshop Goals
This workshop is intended to develop understanding of supermarkets, pull scheduling and
Kanbans. To develop knowledge and skills for deploying supermarkets & Kanbans to control
inventory levels and schedule the production and delivery of raw materials, work-in-process and
finished goods inventories. To practice the deployment of supermarket pull systems using
Kanbans in a live manufacturing, assembly or purchasing process. To identify and quantify the cost
savings from the improved inventory control and production scheduling performance resulting from
the use of pull scheduling.
Workshop Outline
• Introduction to Pull Systems
• Introduction to Supermarkets
• Introduction to Kanbans
• Introduction to Heijunka (leveling)
• Determining Appropriate Inventory Levels
• Designing Supermarkets
• Creating Kanbans for Production Scheduling & Inventory Control
• Determining Cost Savings from the Supermarket Pull System
• Management and Continuous Improvement of the Supermarket Pull System
• Management Reports & Management Review
___________________________________________________________________________
Implementing Five S’s for Workplace Organization & Visual
Management for Continual Process Improvement (4 Days)
Workshop Content
This four-day workshop develops the knowledge and skills for planning, organizing and
implementing the Five S Method for Workplace Organization. Workshop participants will also learn
how the Five S process fits into a total system of Visual Management. Workshop participants will
receive instruction and guided practice in planning and deploying visual management systems for
the continual improvement of process quality, productivity, housekeeping, safety and employee
development. Participants will learn how to create standards for each type of performance and to
use the concept and practice of Visual Controls to integrate those standards into daily practice.
Who Should Attend
This workshop is intended for Champions and Black Belt Candidates responsible for
implementing and managing Lean improvement projects.
Prerequisites
This is the final workshop in the Lean Training System. Participants must have completed
Champion Training and all previous Lean Workshops prior to enrolling in this program.
Workshop Materials
Each workshop participant will receive a Manual with all course materials. Each participant will
also receive a CD ROM with all necessary files, reports, forms, charts, graphs and tables
necessary to plan, organize and lead Lean Project Teams.
Workshop Goals
This workshop develops understanding of the philosophy and process for achieving workplace
organization through the Five S Method. Participants will conduct a Five S Campaign to clean and
organize one or more locations in your plant/office operations. Participants will also utilize Visual
Management Methods to Control process performance in order to “hold the gains” achieved.
Workshop Outline
• Introduction to the Five S Method
• Sort - identify and sort items by frequency of use
• Store – prepare and label storage locations for all items
• Shine – conduct a campaign to repair, clean and shine the work area
• Sustain – implement regular 5 S audits to sustain the improvements
• Spread – apply the lessons learned to other plant/office areas
• Introduction to Visual Management
• How to write Performance Standards
• Making Performance Standards Visual
• Preparing and presenting Management Reports
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