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ABOUT THE PROGRAM — This unique program provides companies the opportunity to provide their employees with a strong foundation in the Lean concepts and tools that are used to drive continuous improvement and achieve world-class business performance. A “first-of-its-kind” in the San Antonio Metropolitan Area, the certification consists of nine “Lean Tools” that can be applied in any business environment. Participants completing the entire series will receive a certificate of completion on Lean Manufacturing from Texas Manufacturing Assistance Center (TMAC).

WHO SHOULD ATTEND — Business Leaders, Operations Managers, Supervisors, Engineers, Buyers, Administrators, Directors and Individuals ready to meet the challenge of continuous improvement.  This class is designed for the novice implementer and not for an advanced practitioner of Lean Manufacturing concepts.

AGENDA —

DAY 1

• Module 1:  Principles of Lean — Gain an understanding of the eight wastes and the Lean Principles designed to eliminate wastes in business processes.  Through hands-on simulations, participants learn about standardized work, workplace organization, visual controls, set-up reductions, batch size reduction, point of use storage, quality at the source, workforce practices and pull systems. 
• Module 2:
  • Value Stream Mapping Current State Part I — Learn how to map the current state of information and material flows using a case study. Participants learn to see the entire value stream for a product.
  • Kaizen Events and Team Facilitation Part I — Understand the difference between Kaizen and Kaizen events.  Learn how to promote, enable, and sustain team effectiveness within your organization.   

DAY 2

• Module 3:  5S Workplace Organization — Covers the basics of sort, set in order, shine, standardize, and sustain. Participants learn how workplace organization and standardization is the foundation for creating a Lean environment.
• Module 4:  Cellular/Flow Manufacturing — Discover the basic elements of Cellular/Flow Manufacturing, which include point of use concepts, workstation design, process layout, work combination and line balancing and Takt time.

DAY 3

• Module 5:  Standard Work — Understand the elements of standard Work: Takt time, work sequence and standard WIP. The instructor will lead the class through the process for developing standard work in a work cell. Standard work is the key to standardization and waste analysis in the cell.
• Module 6:  Pull/Kanban Systems — Learn how to design and implement a visually driven, employee-controlled material replenishment system.

DAY 4

• Module 7:  Total Productive Maintenance — Provides an overview of the TPM methodology to proactively maintain machines and equipment at their peak productivity. Learn to increase overall equipment effectiveness and how it can help avoid interruptions to production.
• Module 8:  Setup Reduction — Introduce the concepts and principles of Quick Changeover and the application of the Single Minute Exchange of Die (SMED) system to analyze changeover tasks and identify improvements.

DAY 5

• Module 9:
  • Value Stream Mapping Future State Part II — Using the current-state map and applying the Lean Principles, participants learn how to identify and eliminate non-value added activities, or wastes, in the value stream to achieve an enhanced future state. 
  • Kaizen Facilitation and Event Examples Part II — By applying basic facilitation skills, learn how skills in team formation, facilitation, management and optimization.  See how these skills have been successfully applied to various business processes in real life case studies. 
• Module 10:  Plant Tour and Graduation — Visit a SAMA Member’s manufacturing facility and receive the Lean Manufacturing Certificate. 

COST —

• SAMA, NBMA & SMMA Member  — $1400 Per Person ($1300 Per Person For Three Or More From One Company)
• Non-Members — $1600 Per Person ($1500 Per Person For Three Or More From One Company)

CANCELLATION DEADLINE 30 DAYS PRIOR TO PROGRAM START DATE

TESTIMONIAL —

Not to downplay the importance of lean but it is what it is.  It has SIMPLIFIED our process and made the routine just that, ROUTINE!

As a light is to food for Pavlov’s dog, large orders created panic seasoned with a little bit of anxiety.  Did we have the materials?  What did we have to build?  Where was the labor going to come from?  And most importantly what order was the priority?  Was it the current shipment or the one dropped in our laps and tagged as “hot”? 

Now with lean, honestly it doesn’t matter if the month is pulling 3,500 or 5,000.  1,000 orders generate the same movement as 1 order.  Removing the waste, the hurdle, roadblocks and surprises, the raw material flows to the customer as finished goods.

From the production standpoint, the workforce’s routine is routine and my managing is now manageable.—Michael J. McIver, Vice President Manufacturing, Pressure Systems International

The Lean Manufacturing Certification Program covers countless ways to eliminate waste (lost profit) and streamline processes.  While some of the concepts taught are simple, others will completely shift paradigms.  Information is presented with heavy emphasis in team work, organizational behavior and, most importantly, what has to be done to successfully implement waste reducing techniques.  All presenters are experts who display extensive knowledge and also understand that common sense has to be a part of any plan to increase efficiency.  While Lean is geared at manufacturing, I have already implemented changes in our distribution system that has saved more money then what it costs to attend - and the class is still in progress.  Management has observed the value of the ideas this course brings to the elimination of unnecessary procedures that are contributing directly to customer service and increasing profitability.  The Lean Manufacturing Course is truly an incredible investment.—Chris Lorenz, Pack-Mark