Lean Six Sigma Yellow Belt Certification


Course Description:
Lean tools and techniques can improve manufacturing in the organization. Working from the perspective of the customer who consumes a product or service, “value” is defined as any action or process that a customer would be willing to pay for. Lean is centered on preserving value with less work. By implementing Lean practices that fit best company culture, value will increased and waste will be reduced. The course allows an in-depth look at the most commonly used Lean tools. The program uses a combination of presentations and discussion, in conjunction with interactive Lean improvement exercises to communicate the concepts of a Lean program to all participants.

Course Topics
Value Stream Mapping:

  • Explains a method to map one of your key processes
  • Identify the process flow
  • Capture critical data
  • Create a current state map
  • Identify waste
  • Evaluate opportunities
  • Create a future state map that identifies the appropriate Lean tools

5S Workplace Organization:

  • Understand 5S (sort, set in order, shine, standardize and sustain)
  • Apply the 5S principles and practices to a targeted areas

Continuous Flow Layouts / Work Cells:

  • Map the current process flow (distance traveled) on a floor plan
  • Identifies reduction opportunities in travel, transportation and handling in order to reduce the process throughput
  • Presents recommendation to management for approval and implementation

Point of Use Storage and Replenishment:

  • Provide parts or materials at point of use
  • Avoid excessive travel by the users
  • Allow the users to help manage their own replenishment
  • Avoid stock-outs
  • Avoids delays & almost eliminates any stock room kitting time

Production or Supplier Pull Replenishment Systems:

  • Synchronizing multiple part production or purchasing
  • Maximizing capacity
  • Reducing lead time
  • Reducing inventory
  • Controlling inventory
  • Managing by sight
  • Reducing exposure to scrap and rework costs
  • Gathering critical process data

Quality Verification & Corrective Action:

  • Establish accurate defect or error reporting
  • Manage a corrective action process
  • Utilizes available resources within the organization to create and promote program

Standard Work Analysis:

  • Standard work is a documented description of what is to be done for each work-related task
  • Assigns an average time for each step
  • Analyzes performance
  • Determines what if any steps can be eliminated

Set Up and Lot Size Reduction:

  • Set Up Reduction (SMED) exercise is videotaped
  • Evaluate each step in a set up process
  • Minimize internal steps
  • Maximize external steps
  • Goal is to reduce both while targeting at least a 50% reduction in the overall setup

Preventive Maintenance:

  • Identifies critical equipment
  • Establishes a scheduled maintenance and assessment (check) of critical parts and lubrication
  • Specifies special cleaning tools
  • Maintains equipment files for manuals, schematics, maintenance schedules, part replacement & part vendor information
  • Avoids equipment downtime and avoid costly delays

Performance Metrics:

  • Establishes a much needed critical World Class Metrics for all departments
  • Communicate to the workforce how the business is performing against pre-established target
  • Analyze & communicate metrics monthly

Course Evaluations Set 1
Course Evaluations Set 2

Always Keep Improving!