Lean Leader Course and Development Program

What you will learn

Overview 

With a constant push to reduce costs and provide products and services faster, there’s no room for activities that don’t add value to the customer. Yet waste and inefficiencies can be disguised and difficult to identify and remove. This course enables you to uncover and eliminate unnecessary activities that slow processes, create waste and add unnecessary cost, so you can focus more on activities that matter most to your customers.

In the Lean Leader Course and Development Program, you quickly develop the skills to apply Lean tools, such as Total Productive Maintenance (TPM), to any environment, including service, manufacturing, healthcare and transactional business. The course provides a comprehensive introduction to key principles and practices for making any process as efficient and low-cost as possible. It also features an applied and results-oriented focus. That means you’ll leave ready to identify improvement opportunities and execute improvement efforts. You’ll learn about leading Lean Kaizen events using BMGI’s five-step SCORE roadmap. You’ll also get a copy of A Team Leader’s Guide to Lean Kaizen Events, which details the method, and includes checklists and templates.

Whether you are new to Lean or have previous knowledge, you’ll find the practical application of this training particularly useful. BMGI experts take the complex topics and make them easy to understand and apply. Those lessons are then reinforced through hands-on simulations. At the end of the course, you’ll walk away with templates and recipes for getting started with each of the Lean tools.

Learning Objectives 

Upon completion of this course, participants will be able to:

  • Lead Kaizen rapid improvement events.
  • Construct value stream maps to guide focused improvements.
  • Identify waste and recognize opportunities where Lean approaches can improve processes within and between departments.
  • Apply the appropriate Lean methods and tools to reduce waste of time, money and people.
  • Have the knowledge to pass the certification exam for Lean Leader.

If you prefer on-site training, we can customize this course for healthcare, manufacturing or transactional service environments.

Certification Option

The Lean Leader certification is designed for future Lean facilitators who want to become proficient in their new roles in a relatively short period of time. Challenging, rigorous and rewarding, BMGI Lean masters shepherd candidates through the following certification requirements:

  • Achieve a 70% or higher grade on all Lean content exams
  • Participate in at least three Kaizen events in the workplace, leading at least two Kaizen events under the tutelage of a BMGI Lean master
  • Submit a report that documents each completed Kaizen event, and participate in an executive report-out for each event
  • Be recommended for certification by a BMGI Lean Master

How you will learn

Classroom 

This course is delivered in a fun, safe and truly engaging workshop environment that motivates and fully prepares participants to implement changes in their organizations. With minimal lecturing, the course is replete with powerful exercises, group work, simulations and meaningful interactions.

One simulation has participants actively attempting to streamline a value stream in light of the many complexities, including people, processes and technology. This hands-on simulation creates a memorable experience when BMGI instructors guide the group through how it can double or triple output by simply modifying the process (with no additional resources or money spent). In addition, the 21 modules of BMGI’s eLearning Lean Series complement the course and provide useful review of the topics taught.

Personal attention is a hallmark of how this course is delivered. Relying on their extensive experience, BMGI instructors pay close attention to various adult learning styles, as they transfer knowledge and skills to participants. Instructors are also available during and after the class to provide mentoring and consulting related to specific issues participants are facing in their organizations.

Certification option:

If you’re participating in the certification option, you begin your program of study by getting paired with a BMGI Lean master who coaches you through every step of the certification process—helping you complete coursework, pass exams, facilitate Kaizen events, prepare reports and present results to management.

Your BMGI Lean master will also support you as you participate in one Kaizen event and facilitate two Kaizen events in your organization—working through more complex Lean-related problems and technicalities and coaching you through any stakeholder and organizational issues involved.

With guidance from your Lean facilitator, you have the freedom to chart your own path, setting timelines and deadlines that work for you. If you have the opportunity to engage in and complete your Kaizen events in a shorter period of time, the program will accommodate this, as it will accommodate a more extended time frame.

Your learning is reinforced with access to BMGI’s state-of-the-art eLearning system, giving you interactive flash-based tutorials, sample exercises and quizzes to test your knowledge. You can also access downloadable templates, tools and case studies as you make the transition from candidate to full-fledged Lean master.

Don’t have time for a full week of training? Sign up for our one-day workshop, How to Run a Kaizen Event, led by BMGI Lean Masters and coming to you at a nearby location.

Course Length: 
5 consecutive days
40 hours of instruction
Classroom Cost: 

Lean Leader Course: $ 2,745

Lean Leader course & certification: $5,245

Classroom Agenda: 
Day One
  • Review
    • Intro to Lean
    • 5 principles of Lean
    • Waste
    • Value
  • SCORE (Kaizen)
    • A Team Leader’s Guide to Lean Kaizen Events
  • Value stream mapping
    • SIPOC
    • Current state map
    • Product family
    • Little’s Law
    • Future state map
  • Simulation
Day Two
  • Review
  • Flow
    • Work load balance
    • Batching
    • Spaghetti diagram
  • Pull
    • Kanban
    • Reorder point
    • Economic order quantity (EOQ)
  • Simulation
Day Three
  • Review
    • 5S
    • Visual management
  • Standard work
    • Pugh matrix
    • Standard work combination sheet
    • Cross training matrix
    • Cycle time loading chart
    • Process capacity table
  • TPM (Total Productive Maintenance)
    • Quality design (maintenance elimination)
    • Autonomous
    • Predictive
    • Preventive
  • Simulation
Day Four
  • Review
  • Setup reduction
    • 5-step method
  • Mistake proofing
    • 4-step method
    • Root cause analysis
    • Mistake proofing matrix
    • Cause-and-effect diagram
    • Prototyping
  • Change management
    • Stakeholder assessment
    • Communication plan
  • Simulation
Day Five
  • Review
  • Simulation
  • SCORE report out

Prefer Training at your Location?

Register for

Lean Leader Course and Development Program

June 05, 2012 4 days Bangkok, TH
July 16, 2012 5 days Denver, CO
October 22, 2012 5 days Denver, CO

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Free problem solving resources

Appropriate for

Anyone who wants to lead Kaizen events
Practitioners in service, manufacturing, healthcare, and transactional business environments
People who are ready to move beyond knowing the concepts to applying the tools of Lean

Course at a Glance

 

Prerequisites

Classroom:

Completion of the following BMGI eLearning modules (part of the Lean for Team Members materials):
Introduction to Lean
The Five Principles of Lean
The Eight Types of Waste

Course Length

Classroom:
5 consecutive days
40 hours of instruction

Cost

Classroom:

Lean Leader Course: $ 2,745

Lean Leader course & certification: $5,245

:

Credits

Classroom: 3.6 CEUs

Course includes

  • A Team Leader’s Guide to Lean Kaizen Events (a $49 value), including a CD-ROM with valuable templates, motivational posters, team charters and usable worksheets.
  • An electronic copy of all templates used during the course.