Certificate in Lean Management

About This Certification

A professional certification programme delivered through LAPT-accredited centres worldwide.

Course Curriculum

4 subjects • 88 chapters • 624 classes

Lean Principles and Philosophy

44 chapters • 100 marks

1 Foundations of Lean Principles and Philosophy 6 classes

1.1 Define Lean: Understand Key Concepts and Terminology

1.2 Explore the Origins: Historical Context of Lean Principles

1.3 Identify the Core Principles: Value, Value Stream, Flow, Pull, and Perfection

1.4 Analyze Waste: The 7 Types of Waste in Lean Management

1.5 Examine the Role of Leadership in Lean Philosophy

1.6 Apply Lean Principles: Case Studies and Real-World Examples

2 The Five Lean Principles: Value, Value Stream, Flow, Pull, and Perfection 6 classes

2.1 Define Value in Lean Management

2.2 Identify the Value Stream in Your Process

2.3 Analyze Flow and Eliminate Waste

2.4 Implement Pull Systems for Efficiency

2.5 Strive for Perfection Through Continuous Improvement

2.6 Integrate the Five Principles in Real-World Scenarios

3 Tools and Techniques for Lean Implementation 6 classes

3.1 Identify Key Lean Tools for Process Optimization

3.2 Analyze the Role of Value Stream Mapping in Lean

3.3 Explore 5S Methodology for Workplace Organization

3.4 Implement Kaizen for Continuous Improvement Strategies

3.5 Apply Root Cause Analysis to Eliminate Waste

3.6 Develop Action Plans for Effective Lean Deployment

4 Leading Lean Transformation: Culture and Change Management 6 classes

4.1 Identify Essential Lean Principles for Cultural Transformation

4.2 Analyze Organizational Barriers to Lean Adoption

4.3 Develop Strategies for Engaging Stakeholders in Lean Change

4.4 Implement Communication Techniques to Foster Lean Mindset

4.5 Evaluate Metrics for Measuring Lean Culture Progress

4.6 Create an Action Plan for Sustaining Lean Transformation

5 Advanced Lean Concepts: Lean Six Sigma and Beyond 6 classes

5.1 Define Lean Six Sigma Principles and Methodologies

5.2 Identify Key Differences Between Lean and Six Sigma

5.3 Explore the DMAIC Framework for Process Improvement

5.4 Apply Statistical Tools in Lean Six Sigma Projects

5.5 Develop a Lean Six Sigma Project Charter

5.6 Evaluate Case Studies of Successful Lean Six Sigma Implementations

1 Understanding Lean Metrics: Foundations and Definitions 6 classes

1.1 Define Key Lean Metrics and Their Importance

1.2 Explore the Differences Between Lead and Lag Metrics

1.3 Identify Common Lean Measurement Tools and Techniques

1.4 Analyze the Role of Value Stream Mapping in Lean Metrics

1.5 Apply Lean Metrics to Assess Process Performance

1.6 Develop a Personal Action Plan for Implementing Lean Metrics

2 Identifying Key Performance Indicators (KPIs) for Lean Success 6 classes

2.1 Define Lean Success: Understanding the Role of KPIs

2.2 Identify Essential Elements of Effective KPIs

2.3 Evaluate Current Performance Metrics: What to Keep and What to Discard

2.4 Establish SMART Criteria for KPI Development

2.5 Analyze Industry Benchmarks: Setting Realistic KPI Targets

2.6 Develop a KPI Dashboard: Visualizing Lean Success Metrics

3 Data Collection Methods for Effective Measurement 6 classes

3.1 Explore Different Data Collection Techniques in Lean Management

3.2 Identify Key Metrics for Lean Measurement Success

3.3 Analyze the Role of Qualitative vs Quantitative Data

3.4 Implement Surveys and Questionnaires for Data Gathering

3.5 Develop Effective Observation Strategies for Data Collection

3.6 Apply Collected Data to Inform Lean Management Decisions

4 Analyzing and Interpreting Lean Metrics 6 classes

4.1 Define Key Lean Metrics for Effective Measurement

4.2 Collecting and Organizing Lean Data Effectively

4.3 Analyzing Lean Metrics to Identify Waste

4.4 Interpreting Trends in Lean Performance Data

4.5 Using Lean Metrics to Drive Continuous Improvement

4.6 Presenting and Communicating Lean Findings Effectively

5 Continuous Improvement: Applying Metrics for Strategic Growth 6 classes

5.1 Define Continuous Improvement and Its Importance

5.2 Identify Key Lean Metrics for Measurement

5.3 Analyze Data to Assess Current Performance

5.4 Set Strategic Growth Goals Using Metrics

5.5 Develop Action Plans Based on Metric Insights

5.6 Evaluate Outcomes and Adjust Strategies After Implementation

1 Understanding Lean Principles and Philosophy 6 classes

1.1 Define Lean Principles and Their Importance

1.2 Identify Key Lean Frameworks and Models

1.3 Explore the Historical Context of Lean Philosophy

1.4 Analyze the Core Concepts of Value Stream Mapping

1.5 Evaluate the Impact of Waste Reduction Techniques

1.6 Apply Lean Principles to Real-World Scenarios

2 Identifying Value and Mapping Value Streams 6 classes

2.1 Define Value from the Customer's Perspective

2.2 Identify Key Value Deliverables in Your Process

2.3 Analyze Current State Value Streams

2.4 Map Value Streams Using Value Stream Mapping Techniques

2.5 Identify Waste in Value Streams for Improvement Opportunities

2.6 Develop an Action Plan to Enhance Value Streams

3 Eliminating Waste: Lean Tools and Techniques 6 classes

3.1 Identify and Define Types of Waste in Lean Management

3.2 Analyze the Value Stream to Spot Improvement Opportunities

3.3 Utilize 5S Methodology for Workplace Organization

3.4 Apply Kaizen Principles for Continuous Improvement

3.5 Implement Just-In-Time (JIT) Practices to Reduce Inventory Waste

3.6 Evaluate Lean Metrics to Measure Waste Reduction Success

4 Creating a Lean Culture: Leadership and Engagement 6 classes

4.1 Define Lean Culture and Its Importance in Leadership

4.2 Identify Key Leadership Behaviors That Foster Engagement

4.3 Develop Strategies for Communicating Lean Principles Effectively

4.4 Implement Tools for Encouraging Employee Participation in Lean Initiatives

4.5 Analyze Case Studies of Successful Lean Culture Implementations

4.6 Create an Action Plan for Sustaining Lean Culture in Your Organization

5 Implementing and Sustaining Lean Strategies 6 classes

5.1 Identify Key Lean Principles for Effective Implementation

5.2 Analyze Current Processes for Lean Opportunities

5.3 Develop a Lean Implementation Plan with Stakeholder Input

5.4 Utilize Tools and Techniques for Lean Strategy Execution

5.5 Measure and Monitor Lean Strategy Performance Metrics

5.6 Create a Sustainability Plan for Long-term Lean Success

2 Identifying and Mapping Value Streams 6 classes

2.1 Define Value Streams in Lean Context

2.2 Identify Key Components of Value Streams

2.3 Analyze Current State Value Stream Maps

2.4 Distinguish Between Value-Adding and Non-Value-Adding Activities

2.5 Create Future State Value Stream Maps

2.6 Implement Strategies for Value Stream Optimization

3 Implementing Lean Tools and Techniques 6 classes

3.1 Identify Key Lean Tools for Process Improvement

3.2 Analyze Waste Using the 7 Lean Principles

3.3 Apply 5S Methodology for Workplace Organization

3.4 Implement Value Stream Mapping to Enhance Workflow

3.5 Utilize Kaizen for Continuous Improvement Initiatives

3.6 Develop a Lean Transformation Plan for Your Organization

4 Advanced Lean Frameworks: Six Sigma Integration 6 classes

4.1 Analyze the Core Principles of Six Sigma

4.2 Compare Lean and Six Sigma Methodologies

4.3 Identify Key Tools Used in Six Sigma Projects

4.4 Explore Real-World Applications of Lean and Six Sigma Integration

4.5 Develop a Six Sigma Project Charter for a Lean Environment

4.6 Assess the Impact of Six Sigma on Lean Operations Performance

5 Cultivating a Lean Culture and Leadership 6 classes

5.1 Define Lean Culture and Its Core Principles

5.2 Identify Key Characteristics of Lean Leadership

5.3 Assess Current Organizational Culture and Readiness for Lean

5.4 Develop Strategies to Foster a Lean Mindset Among Teams

5.5 Create an Action Plan for Implementing Lean Leadership Practices

5.6 Evaluate the Impact of Lean Culture on Organizational Performance

1 Understanding the Foundations of Change Management in Lean Operations 6 classes

1.1 Identify Key Principles of Change Management in Lean Operations

1.2 Analyze the Role of Leadership in Change Management

1.3 Explore Common Challenges in Implementing Change

1.4 Examine Tools and Techniques for Effective Change Implementation

1.5 Develop a Change Management Plan for Lean Initiatives

1.6 Evaluate the Impact of Change on Team Dynamics and Culture

2 Key Theories and Models of Change Management 6 classes

2.1 Explore the Foundations of Change Management Theories

2.2 Analyze Lewin's Change Management Model

2.3 Apply Kotter's 8-Step Process for Leading Change

2.4 Evaluate the ADKAR Model in Lean Operations

2.5 Compare Top Change Management Frameworks

2.6 Develop a Change Management Strategy for Lean Implementation

3 Identifying Resistance to Change in Lean Environments 6 classes

3.1 Analyze Common Sources of Resistance in Lean Environments

3.2 Identify Psychological Barriers to Change

3.3 Assess the Impact of Organizational Culture on Change Acceptance

3.4 Recognize Emotional Responses to Change Among Team Members

3.5 Develop Strategies to Communicate Change Effectively

3.6 Create an Action Plan to Overcome Resistance in Your Team

4 Developing and Implementing a Change Management Strategy 6 classes

4.1 Analyze Current Organizational Readiness for Change

4.2 Identify Key Stakeholders and Their Roles in Change Initiatives

4.3 Develop a Comprehensive Change Management Plan

4.4 Communicate the Change Vision Effectively to the Team

4.5 Implement Change Strategies Using Lean Principles

4.6 Evaluate Change Outcomes and Adapt Strategies Accordingly

5 Measuring and Sustaining Change in Lean Operations 6 classes

5.1 Define Key Metrics for Measuring Change in Lean Operations

5.2 Analyze Data Collection Methods for Lean Change Management

5.3 Evaluate the Impact of Change Using Lean Performance Metrics

5.4 Develop Strategies for Sustaining Change in Lean Operations

5.5 Implement Continuous Improvement Cycles in Lean Practices

5.6 Communicate Change Effectively to Engage Stakeholders

1 Understanding Lean: History and Principles 6 classes

1.1 Explore the Origins of Lean Principles

1.2 Identify Key Historical Milestones in Lean Development

1.3 Define Core Lean Principles and Their Importance

1.4 Analyze the Role of Waste in Lean Thinking

1.5 Discuss the Evolution of Lean Methodologies

1.6 Apply Lean Principles to Real-World Scenarios

2 Identifying Waste: The Eight Types of Waste 6 classes

2.1 Define and Understand the Eight Types of Waste

2.2 Identify Overproduction and Its Impact on Efficiency

2.3 Recognize Waiting Time and Strategies to Minimize It

2.4 Analyze Transport Waste in Your Organization

2.5 Evaluate Excess Inventory and Implement Control Measures

2.6 Apply Lean Techniques to Reduce Waste in a Real-World Scenario

3 Value Stream Mapping: Tools for Analysis 6 classes

3.1 Define Value Stream Mapping and Its Significance

3.2 Identify Components of a Value Stream Map

3.3 Analyze Current State: Creating a Value Stream Map

3.4 Identify Waste in the Current State Map

3.5 Design a Future State Value Stream Map

3.6 Develop an Action Plan for Implementing Improvements

4 Lean Methodologies: Kaizen and 5S Implementation 6 classes

4.1 Understand Kaizen: The Philosophy of Continuous Improvement

4.2 Identify the Key Principles of 5S Methodology

4.3 Assess Current Processes for Kaizen Opportunities

4.4 Implementing the 5S System: Steps and Best Practices

4.5 Engage Teams: Fostering a Culture of Kaizen

4.6 Measure Success: Evaluating Kaizen and 5S Outcomes

5 Sustaining Lean Practices: Culture and Leadership 6 classes

5.1 Identify Key Leadership Traits for Lean Sustainability

5.2 Analyze Organizational Culture's Impact on Lean Initiatives

5.3 Develop Strategies to Foster a Lean Mindset Among Teams

5.4 Implement Communication Techniques for Lean Success

5.5 Design a Continuous Improvement Framework for Lean Practices

5.6 Evaluate and Adjust Leadership Approaches for Lean Sustainability

1 Understanding Lean Principles: Reducing Waste and Increasing Value 6 classes

1.1 Define Lean Principles and Their Importance

1.2 Identify Different Types of Waste in Processes

1.3 Analyze the Impact of Waste on Value Creation

1.4 Explore Tools for Waste Reduction

1.5 Apply Lean Techniques to a Real-World Scenario

1.6 Develop a Personal Action Plan for Implementing Lean Principles

2 Six Sigma Fundamentals: Achieving Quality Improvement 6 classes

2.1 Define Key Six Sigma Concepts and Terminology

2.2 Explore the DMAIC Framework for Process Improvement

2.3 Identify and Measure Process Performance Metrics

2.4 Analyze Data to Identify Root Causes of Defects

2.5 Implement Solutions to Reduce Variation and Improve Quality

2.6 Sustain Improvements and Standardize Best Practices

3 Integrating Lean and Six Sigma: A Synergistic Approach 6 classes

3.1 Define Lean and Six Sigma: Key Concepts and Principles

3.2 Identify the Benefits of Integrating Lean and Six Sigma

3.3 Explore the Synergies Between Lean and Six Sigma Methodologies

3.4 Analyze Real-World Case Studies: Success Stories of Integration

3.5 Develop an Integration Strategy: Framework for Implementation

3.6 Create an Action Plan: Steps to Sustain Lean and Six Sigma Integration

4 Tools and Techniques: Implementing Lean and Six Sigma in Practice 6 classes

4.1 Identify Lean Principles and Their Benefits

4.2 Understand the Fundamentals of Six Sigma

4.3 Explore Common Lean Tools for Efficiency

4.4 Utilize Six Sigma Techniques for Quality Improvement

4.5 Integrate Lean and Six Sigma for Process Optimization

4.6 Develop an Action Plan for Implementing Lean and Six Sigma

5 Leadership in Process Excellence: Cultivating a Continuous Improvement Culture 6 classes

5.1 Define Continuous Improvement and Its Importance in Leadership

5.2 Identify Key Leadership Traits that Foster a Continuous Improvement Culture

5.3 Explore Tools and Techniques for Enhancing Team Engagement in Process Excellence

5.4 Analyze Real-World Case Studies on Successful Continuous Improvement Leadership

5.5 Develop a Personal Action Plan to Implement Continuous Improvement Strategies

5.6 Create a Communication Plan for Promoting Continuous Improvement Initiatives

1 Fundamentals of Lean Methodologies 6 classes

1.1 Define Lean Methodologies and Their Core Principles

1.2 Identify Waste Types and Their Impact on Processes

1.3 Explore the Value Stream Mapping Technique

1.4 Implement the 5S Framework for Workplace Organization

1.5 Demonstrate Continuous Improvement through Kaizen Practices

1.6 Apply Lean Tools to Real-World Scenarios

2 Identifying and Eliminating Waste 6 classes

2.1 Define Waste in Lean Methodologies

2.2 Identify Types of Waste in Processes

2.3 Assess Your Current Processes for Waste

2.4 Analyze Root Causes of Identified Waste

2.5 Develop Strategies to Eliminate Waste

2.6 Implement Waste Reduction Solutions and Measure Impact

3 Value Stream Mapping Techniques 6 classes

3.1 Identify Key Components of Value Stream Mapping

3.2 Analyze Current State Value Stream Maps

3.3 Design Future State Value Stream Maps

3.4 Assess Waste within Value Streams

3.5 Implement Continuous Improvement Strategies

3.6 Facilitate Value Stream Mapping Workshops

4 Implementing Continuous Improvement Practices 6 classes

4.1 Identify Opportunities for Continuous Improvement

4.2 Analyze Current Processes Using Lean Tools

4.3 Develop a Continuous Improvement Plan

4.4 Implement Kaizen Events to Foster Change

4.5 Measure and Evaluate Improvements Effectively

4.6 Sustain Continuous Improvement Through Employee Engagement

5 Lean Leadership and Culture Transformation 6 classes

5.1 Define Lean Leadership Principles

5.2 Identify Characteristics of a Lean Culture

5.3 Assess Current Organizational Culture

5.4 Develop Strategies for Culture Transformation

5.5 Implement Lean Leadership Practices

5.6 Evaluate the Impact of Lean Transformation

1 Understanding Lean Principles and Six Sigma Integration 6 classes

1.1 Define Lean Principles and Their Importance in Six Sigma

1.2 Identify Key Differences Between Lean and Six Sigma Methodologies

1.3 Explore the Seven Wastes and Their Impact on Efficiency

1.4 Analyze the Value Stream Mapping Process in Lean Six Sigma

1.5 Apply Lean Tools to Real-World Six Sigma Projects

1.6 Develop a Lean-Six Sigma Integration Plan for Continuous Improvement

2 Identifying Waste: The Lean Perspective 6 classes

2.1 Define Value from the Customer's Perspective

2.2 Identify Types of Waste in Processes

2.3 Explore the Seven Wastes of Lean Principle

2.4 Analyze Real-World Examples of Waste

2.5 Evaluate the Impact of Waste on Business Performance

2.6 Develop Strategies to Eliminate Waste in Your Organization

3 Value Stream Mapping and Analysis 6 classes

3.1 Define Value Stream Mapping and Its Importance

3.2 Identify Components of a Value Stream Map

3.3 Analyze Current State Value Stream Maps

3.4 Identify Waste in Value Stream Analysis

3.5 Develop Future State Value Stream Maps

3.6 Implement Value Stream Improvements and Measure Results

4 Implementing Lean Tools in Six Sigma Projects 6 classes

4.1 Identify Key Lean Tools for Six Sigma Integration

4.2 Analyze the Role of Value Stream Mapping in Lean Six Sigma

4.3 Apply the 5S Methodology to Improve Workflow in Projects

4.4 Utilize Kaizen for Continuous Improvement in Six Sigma Initiatives

4.5 Develop Standard Operating Procedures using Lean Techniques

4.6 Evaluate the Impact of Lean Tools on Six Sigma Project Outcomes

5 Sustaining Lean Improvements: Culture and Leadership 6 classes

5.1 Analyze the Role of Leadership in Sustaining Lean Improvements

5.2 Identify Cultural Barriers to Lean Transformation

5.3 Develop Strategies for Cultivating a Lean Culture

5.4 Engage Teams in Continuous Improvement Processes

5.5 Measure and Assess the Impact of Lean Initiatives

5.6 Create a Roadmap for Long-term Lean Sustainability

Lean Tools: Value Stream Mapping, 5S and Kanban

18 chapters • 100 marks

1 Understanding Lean Principles and Practices 6 classes

1.1 Define Lean Principles and Their Importance

1.2 Identify Key Lean Tools and Their Functions

1.3 Explore Value Stream Mapping Techniques

1.4 Analyze the Role of Waste Elimination in Lean

1.5 Implement 5S Methodology in Workplace Organization

1.6 Evaluate the Impact of Continuous Improvement Cycles

2 Mapping the Value Stream: Tools and Techniques 6 classes

2.1 Understand Value Stream Mapping Basics

2.2 Identify Key Elements of the Value Stream

2.3 Analyze Current State of Value Stream

2.4 Identify Waste within the Value Stream

2.5 Develop Future State Value Stream Map

2.6 Implement Action Plans to Optimize Value Stream

3 Implementing 5S for Workplace Organization 6 classes

3.1 Define and Understand the 5S Methodology

3.2 Identify Key Tools for Each Step of 5S

3.3 Conduct a ‘Sort’ Audit in Your Workplace

3.4 Develop a 'Set in Order' Plan for Efficient Layout

3.5 Establish 'Shine' Standards for Workplace Cleaning

3.6 Create a Sustaining Strategy for Ongoing 5S Success

4 Applying Kaizen for Continuous Improvement 6 classes

4.1 Understand the Principles of Kaizen for Continuous Improvement

4.2 Identify Areas for Improvement Using the Kaizen Approach

4.3 Apply the PDCA Cycle in Kaizen Initiatives

4.4 Develop a Kaizen Action Plan for Team Engagement

4.5 Measure the Effectiveness of Kaizen Implementations

4.6 Sustain Continuous Improvement Through Kaizen Culture

5 Advanced Lean Tools: Kanban and Just-In-Time 6 classes

5.1 Understand Kanban Principles and History

5.2 Identify Different Types of Kanban Systems

5.3 Implementing Kanban Boards for Visual Management

5.4 Explore Just-In-Time (JIT) Concepts and Benefits

5.5 Analyze the Impact of JIT on Inventory Management

5.6 Integrate Kanban and JIT for Streamlined Production

1 Understanding Value Streams: Definitions and Importance 6 classes

1.1 Define Value Streams and Their Components

1.2 Explain the Importance of Value Stream Mapping

1.3 Identify Different Types of Value Streams

1.4 Describe the Role of Stakeholders in Value Streams

1.5 Analyze the Impact of Inefficiencies in Value Streams

1.6 Create a Value Stream Map for a Simple Process

2 Identifying Current State: Mapping Techniques and Tools 6 classes

2.1 Define Current State: Understanding Value Stream Mapping Basics

2.2 Identify Key Elements: Components of a Value Stream Map

2.3 Select Mapping Techniques: Tools for Effective Visualization

2.4 Gather Data: Collecting Relevant Information for Mapping

2.5 Create a Value Stream Map: Step-by-Step Mapping Process

2.6 Analyze Current State: Identifying Waste and Opportunities for Improvement

3 Analyzing Value Stream Maps: Identifying Waste and Opportunities 6 classes

3.1 Understand the Fundamentals of Value Stream Mapping

3.2 Identify Key Components of a Value Stream Map

3.3 Analyze Current State and Spot Inefficiencies

3.4 Categorize Types of Waste in Value Streams

3.5 Develop Future State Value Stream Improvement Strategies

3.6 Create an Action Plan to Implement Improvements

4 Designing Future State Value Streams: Best Practices 6 classes

4.1 Analyze Current State Value Streams

4.2 Identify Value-Adding Activities in Processes

4.3 Define Customer Value and Requirements

4.4 Visualize Future State Value Streams

4.5 Develop Strategies for Eliminating Waste

4.6 Create an Action Plan for Implementation

5 Implementing Changes: Action Plans and Performance Metrics 6 classes

5.1 Develop Action Plans for Effective Change Implementation

5.2 Identify Key Performance Metrics for Tracking Improvements

5.3 Align Action Plans with Strategic Organizational Goals

5.4 Engage Stakeholders in the Change Process

5.5 Monitor Performance Metrics for Continuous Improvement

5.6 Evaluate the Impact of Changes on Value Streams

1 Understanding Lean Principles and Tools 6 classes

1.1 Identify Core Lean Principles for Process Improvement

1.2 Analyze Waste Types in Business Processes

1.3 Apply the 5S Methodology for Workplace Organization

1.4 Utilize Value Stream Mapping to Enhance Efficiency

1.5 Implement Kanban Systems for Improved Workflow

1.6 Measure Success with Key Performance Indicators in Lean

2 Value Stream Mapping and Analysis 6 classes

2.1 Define Value Stream Mapping and Its Importance

2.2 Identify Key Components of a Value Stream Map

2.3 Analyze Current State Value Streams

2.4 Identify Waste in Value Streams Using Lean Principles

2.5 Develop Future State Value Streams for Improvement

2.6 Create a Value Stream Mapping Action Plan

3 The 5S Methodology for Workplace Organization 6 classes

3.1 Define and Explain the 5S Methodology in Lean Management

3.2 Identify the Five Steps of 5S: Sort, Set in Order, Shine, Standardize, Sustain

3.3 Analyze the Benefits of Implementing 5S in the Workplace

3.4 Conduct a 5S Audit: Assess Current Workplace Organization

3.5 Develop an Action Plan for Each Step of 5S Implementation

3.6 Create a 5S Sustainability Strategy for Ongoing Improvement

4 Kaizen: Continuous Improvement Strategies 6 classes

4.1 Understand the Principles of Kaizen for Continuous Improvement

4.2 Identify Opportunities for Kaizen in Your Workplace

4.3 Implement Kaizen Practices: Tools and Techniques Overview

4.4 Facilitate a Kaizen Event: Steps to Success

4.5 Measure and Analyze the Impact of Kaizen Initiatives

4.6 Cultivate a Kaizen Culture: Engaging Your Team in Continuous Improvement

5 Implementing Lean Tools in Projects 6 classes

5.1 Identify Key Lean Tools for Project Implementation

5.2 Analyze Project Constraints and Opportunities for Lean Application

5.3 Develop a Lean Tool Selection Matrix for Your Project

5.4 Create a Plan for Integrating Lean Tools into Project Workflow

5.5 Measure and Monitor Lean Tool Effectiveness in Real-Time

5.6 Iterate and Improve: Adjust Lean Tools Based on Project Feedback

16 Kanban and Pull Systems in Practice 10 classes

16.1 Push Versus Pull Production

16.2 Kanban Cards and Signals

16.3 Two Bin and Visual Replenishment

16.4 Calculating the Number of Kanbans

16.5 Setting Up a Supermarket Stock Area

16.6 Sequencing and Levelled Production

16.7 Limiting Work in Progress

16.8 Kanban Boards for Office Work

16.9 Troubleshooting a Pull System

16.10 Measuring Flow and Lead Time

17 Quick Changeover and Setup Reduction 10 classes

17.1 Why Long Changeovers Hurt Flow

17.2 Internal and External Setup Tasks

17.3 Recording a Changeover on Video

17.4 Converting Internal Tasks to External

17.5 Standard Tools and Fixtures

17.6 Parallel Tasks During Changeover

17.7 Checklists for Changeover Steps

17.8 Timing and Tracking Setup Times

17.9 Safety During Rapid Changeovers

17.10 Sustaining Smaller Batch Sizes

18 Standard Work and Workplace Visual Control 10 classes

18.1 Purpose of Standard Work

18.2 Takt Time and Cycle Time

18.3 Standard Work Combination Sheets

18.4 Observing and Timing Operators

18.5 Writing Work Instructions with Photos

18.6 Visual Controls and Andon Signals

18.7 Floor Markings and Shadow Boards

18.8 Layout Changes for Smoother Flow

18.9 Auditing Standard Work Daily

18.10 Updating Standards After Improvement

Lean Operations and Process Improvement

12 chapters • 100 marks

1 Introduction to Operations and Value Creation 10 classes

1.1 What Operations Management Means

1.2 Inputs Processes and Outputs

1.3 Customers and Value

1.4 Types of Operations Systems

1.5 Goods Versus Services Operations

1.6 Measuring Operational Performance

1.7 Supply Chain Basics for Operators

1.8 Roles Within an Operations Team

1.9 Operations Strategy at a Glance

1.10 Reading an Operations Dashboard

2 Lean Thinking and the Eight Wastes 10 classes

2.1 Origins of Lean Thinking

2.2 Defining Value from the Customer View

2.3 Overproduction and Waiting

2.4 Transport and Motion Waste

2.5 Over-Processing and Defects

2.6 Excess Inventory Waste

2.7 Unused Talent as Waste

2.8 Waste Walks in the Workplace

2.9 Recording Waste Observations

2.10 Ranking Waste by Impact

3 Process Observation and Time Study 10 classes

3.1 Planning a Process Observation

3.2 Go and See at the Workplace

3.3 Recording Cycle Times Accurately

3.4 Using Stopwatch and Video

3.5 Work Sampling Basics

3.6 Calculating Takt and Cycle Time

3.7 Identifying Value Adding Steps

3.8 Spotting Non-Value Adding Steps

3.9 Presenting Observation Findings

3.10 Respecting Staff During Observation

4 Workplace Organisation and Housekeeping 10 classes

4.1 Sort Set in Order and Shine

4.2 Standardise and Sustain Routines

4.3 Red Tag Area Practice

4.4 Marking Locations for Tools

4.5 Cleaning as Inspection

4.6 Housekeeping Audits and Scoring

4.7 Before and After Photo Records

4.8 Safety Benefits of Tidy Workplaces

4.9 Involving the Team in Weekly Routines

4.10 Keeping Standards Alive Over Time

5 Flow and Layout Improvement 10 classes

5.1 Principles of Smooth Flow

5.2 Spaghetti Diagrams of Movement

5.3 Cellular Layout Basics

5.4 Balancing Work Across Operators

5.5 Reducing Handoffs and Queues

5.6 Batch Size and Lead Time

5.7 Moving Materials to the Point of Use

5.8 Layout Trials on a Small Scale

5.9 Ergonomics in Layout Design

5.10 Measuring Gains from Layout Change

6 Inventory and Material Handling Control 10 classes

6.1 Types of Inventory in a Business

6.2 Stock Counting and Accuracy

6.3 First In First Out Handling

6.4 Reorder Points and Safety Stock

6.5 Visual Stock Replenishment

6.6 Storage Location Management

6.7 Safe Manual Handling Practice

6.8 Obsolete and Slow Moving Stock

6.9 Inventory Cost and Cash Impact

6.10 Reviewing Stock with Suppliers

7 Quality at the Source and Error Proofing 10 classes

7.1 Cost of Defects in Operations

7.2 Inspecting at the Point of Work

7.3 Stop and Fix Practices

7.4 Simple Mistake Proofing Devices

7.5 Checklists to Prevent Errors

7.6 Defect Tracking Boards

7.7 First Pass Yield Measurement

7.8 Containing a Defect Quickly

7.9 Operator Involvement in Quality

7.10 Standard Reaction Plans

8 Equipment Reliability and Basic Maintenance 10 classes

8.1 Why Equipment Downtime Hurts

8.2 Operator Cleaning and Inspection

8.3 Daily Equipment Checklists

8.4 Planned Versus Breakdown Maintenance

8.5 Lubrication and Basic Care

8.6 Recording Downtime Reasons

8.7 Overall Equipment Effectiveness Basics

8.8 Handling Minor Stoppages

8.9 Spare Parts Visibility

8.10 Working Safely Around Machines

9 Demand, Planning and Scheduling 10 classes

9.1 Understanding Customer Demand

9.2 Simple Forecasting Methods

9.3 Capacity Versus Demand

9.4 Production Schedules for Small Teams

9.5 Levelling Workload Through the Week

9.6 Handling Urgent Orders

9.7 Daily Production Meetings

9.8 Visual Schedule Boards

9.9 Managing Backlog and Overtime

9.10 Reviewing Schedule Adherence

10 Daily Management and Visual Performance 10 classes

10.1 Purpose of Daily Management

10.2 Choosing Meaningful Measures

10.3 Building a Performance Board

10.4 Short Interval Control

10.5 Daily Huddles That Work

10.6 Escalating Problems Quickly

10.7 Tracking Actions to Closure

10.8 Leader Standard Work Basics

10.9 Recognising Team Results

10.10 Reviewing Boards for Relevance

11 Small Improvement Projects and Team Problem Solving 10 classes

11.1 Selecting an Improvement Topic

11.2 Writing a Clear Problem Statement

11.3 Plan Do Check Act Cycle

11.4 Basic Cause Finding Tools

11.5 Five Whys in Practice

11.6 Brainstorming Solutions Fairly

11.7 Trialling Ideas on a Small Scale

11.8 Measuring Before and After

11.9 Standardising the Improvement

11.10 Presenting Results to Management

12 Sustaining Operational Improvement and Capstone 10 classes

12.1 Building a Continuous Improvement Habit

12.2 Suggestion Systems for Staff Ideas

12.3 Coaching Teammates in Improvement

12.4 Resistance and How to Handle It

12.5 Audit Routines That Hold the Gains

12.6 Linking Improvement to Customer Results

12.7 Sharing Best Practice Across Teams

12.8 Reporting Savings Honestly

12.9 Planning the Next Improvement Cycle

12.10 Capstone Improvement Walkthrough

Root Cause Analysis and Problem Solving

14 chapters • 100 marks

1 Understanding Root Cause Analysis Concepts 6 classes

1.1 Define Root Cause Analysis and Its Importance

1.2 Explore Common Root Cause Analysis Techniques

1.3 Identify Key Terminology in Root Cause Analysis

1.4 Analyze Case Studies Demonstrating Root Cause Analysis

1.5 Apply Root Cause Analysis in Real-World Scenarios

1.6 Evaluate the Effectiveness of Root Cause Analysis Strategies

2 Tools and Techniques for Root Cause Identification 6 classes

2.1 Identify Key Concepts of Root Cause Analysis

2.2 Explore the 5 Whys Technique for Problem Solving

2.3 Apply Fishbone Diagram for Visual Analysis

2.4 Utilize Pareto Chart for Prioritizing Causes

2.5 Assess the Role of Failure Mode and Effects Analysis (FMEA)

2.6 Develop an Action Plan Based on Root Cause Findings

3 Data Collection and Analysis for Root Cause Analysis 6 classes

3.1 Identify Key Data Sources for Root Cause Analysis

3.2 Design Effective Data Collection Methods

3.3 Analyze Collected Data for Patterns and Trends

3.4 Utilize Statistical Tools to Interpret Data

3.5 Validate Data Integrity and Reliability

3.6 Apply Findings to Develop Actionable Insights

4 Implementing Solutions and Countermeasures 6 classes

4.1 Identify Potential Solutions for Root Causes

4.2 Evaluate Solution Feasibility and Impact

4.3 Design Effective Countermeasures

4.4 Develop an Implementation Plan for Solutions

4.5 Monitor and Adjust Solutions Post-Implementation

4.6 Document Lessons Learned and Best Practices

5 Evaluating Effectiveness and Continuous Improvement 6 classes

5.1 Assess Current Performance Metrics

5.2 Identify Gaps in Process Effectiveness

5.3 Implement Root Cause Analysis Techniques

5.4 Develop Action Plans for Improvement

5.5 Monitor and Measure Improvement Outcomes

5.6 Foster a Culture of Continuous Improvement

6 Defining and Scoping a Problem 10 classes

6.1 Recognising a Real Problem

6.2 Symptoms Versus Causes

6.3 Gathering Facts at the Scene

6.4 Writing a Problem Statement

6.5 Using Is and Is Not Analysis

6.6 Sizing the Impact on Customers

6.7 Setting Scope and Boundaries

6.8 Forming the Problem Solving Team

6.9 Assigning Roles and Timelines

6.10 Opening a Problem Log

7 Immediate Containment and Interim Actions 10 classes

7.1 Protecting the Customer First

7.2 Stopping the Flow of Defects

7.3 Sorting and Segregating Suspect Stock

7.4 Tagging and Quarantine Procedures

7.5 Recalling Affected Deliveries

7.6 Interim Controls and Extra Checks

7.7 Communicating Containment to Teams

7.8 Documenting Containment Evidence

7.9 Deciding When Containment Can End

7.10 Safety Considerations During Containment

8 Five Whys and Cause Chains 10 classes

8.1 Principles of Asking Why

8.2 Preparing for a Why Session

8.3 Running a Five Whys Step by Step

8.4 Avoiding Blame in Why Questions

8.5 Checking Each Answer with Evidence

8.6 Branching Why Trees

8.7 Reaching a True Root Cause

8.8 Common Mistakes in Why Analysis

8.9 Practising on Equipment Failures

8.10 Recording Why Results

9 Fishbone and Cause Mapping 10 classes

9.1 Structure of a Cause and Effect Diagram

9.2 Choosing Cause Categories

9.3 Brainstorming with the Team

9.4 Grouping and Sorting Ideas

9.5 Marking Likely Causes

9.6 Testing Causes with Observation

9.7 Cause Mapping a Sequence of Events

9.8 Linking Causes to Evidence

9.9 Using Fishbone Diagrams in Service Work

9.10 Reviewing Diagrams for Gaps

10 Data Tools for Finding Causes 10 classes

10.1 Choosing the Right Data Tool

10.2 Check Sheets for Cause Counts

10.3 Pareto Analysis to Find the Vital Few

10.4 Histograms of Process Results

10.5 Scatter Plots for Cause Testing

10.6 Stratifying by Time and Location

10.7 Comparing Good and Bad Conditions

10.8 Simple Control Chart Reading

10.9 Reading Trends and Cycles

10.10 Telling a Story with Data

11 Failure Analysis for Equipment and Process 10 classes

11.1 Types of Equipment Failure

11.2 Inspecting Failed Parts Safely

11.3 Preserving Evidence

11.4 Timeline of Events Method

11.5 Barrier and Change Analysis

11.6 Human Factors and Procedure Gaps

11.7 Environmental and Material Causes

11.8 Comparing Similar Machines

11.9 Escape Point Analysis

11.10 Confirming Root Cause by Test

12 Corrective and Preventive Action Planning 10 classes

12.1 Difference Between Correction and Corrective Action

12.2 Writing Clear Corrective Actions

12.3 Selecting Practical Solutions

12.4 Weighing Cost and Benefit

12.5 Assigning Owners and Deadlines

12.6 Trial Runs Before Full Roll Out

12.7 Updating Procedures and Training

12.8 Preventive Actions Across Similar Processes

12.9 Tracking Actions to Closure

12.10 Management Review of Open Actions

13 Structured Problem Solving Reports 10 classes

13.1 Reasons for Structured Reports

13.2 Report Format Step by Step

13.3 Writing Clear Technical Statements

13.4 Including Evidence and Photos

13.5 Describing Root Cause Plainly

13.6 Summarising Actions and Results

13.7 Customer Facing Problem Reports

13.8 Peer Review Before Submission

13.9 Presenting a Problem Report Orally

13.10 Filing and Retrieving Reports

14 Verification, Lessons Learned and Practice 10 classes

14.1 Measuring Whether the Fix Worked

14.2 Setting Verification Periods

14.3 Checking for Recurrence

14.4 Spreading Lessons to Other Teams

14.5 Building a Lessons Learned Library

14.6 Coaching Others in Problem Solving

14.7 Common Pitfalls and Biases

14.8 Working a Full Case Study

14.9 Peer Assessment of a Case

14.10 Capstone Problem Solving Presentation

MGT-C03
400 total marks
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Certificate in Lean Management

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