SME, AME, SHINGO: LEAN CERTIFICATION
LOCATION:
US-based; remote personal study; exam and course locations at sites across US.
CERTIFICATES/CERTIFICATION OFFERED:
Bronze level,
Silver level,
Gold level
Certification is valid for 3 years before re-certification or pursuit of the next level is required.
CONTENT COVERED:
The Lean Body of Knowledge – lean content divided into 4 modules (Cultural Enablers,
Continuous Process Improvement, Consistent Lean Enterprise Culture, Business Results)
(http://www.sme.org/downloads/cert/lean/BOK.pdf) as well as the following
recommended/required reading…
Bronze Level
- Gemba Kaizen, Masaaki Imai
- Lean Production Simplified, Pascal Dennis
- Lean Thinking, James P. Womack and Daniel T. Jones
- Learning to See, Mike Rother and John Shook
Silver Level
- Practical Lean Accounting, Brian Maskell and Bruce Baggaley
- The Lean Design Guidebook, Ronald Mascitelli
- Office Kaizen, William Lareau
- Real Numbers, Orest J. Fiume and Jean E. Cunningham
- The Toyota Way, Jeffrey Liker
- Toyota Production System, Taiichi Ohno
Gold Level
- Creating a Lean Culture, David Mann
- Lean Solutions, James P. Womack and Daniel T. Jones
- Lean Transformation, Bruce A. Henderson and Jorge L. Larco
- Natural Capitalism, Paul Hawken, Amory Lovins, L. Hunter Lovins
- Today & Tomorrow, Henry Ford
TARGET PARTICIPANT/PROGRAM GOAL:
Bronze level: Demonstrates solid understanding of basic lean principles and tools, and
ability in tactical implementation that drives improvement and shows measurable
results.
Silver level: Recognition of experience as a lean project leader on value stream
transformations. It represents career progression in knowledge and responsibility as
one becomes a senior employee and team leader.
Gold level: Recognition of understanding of all aspects of Lean transformation across an
entire enterprise. It represents career progression to a point of influence and authority
over assets, processes and people.
INSTRUCTION/LEARNING METHOD:
1. Independent reading/study
2. Independent application of principles to own workplace
3. Bronze only: 2 day review course (optional) ($549, or $499 for AME members)
4. Bronze only: Work with a Lean mentor (optional)
PRE-REQUISITE(S):
Bronze level: [none]
Silver level: valid/current Bronze certification
Gold level: valid/current Silver certification
CERTIFICATION REQUIREMENTS/ASSESSMENT(S):
Bronze level
1. Written exam based on recommended reading; open book (3 hours, 170 questions)
2. Submission and evaluation of experience portfolio. Must document events, projects or
activities to which specific lean principles and tools were applied and the results.
Silver level
1. Written exam based on recommended reading; open book (3 hours, 150 questions)
2. Submission and evaluation of an experience portfolio. Must provide documentation that
participant has led a lean transformation of a complete value stream. Must also show
participation in 5 lean events, projects or activities that applied and integrated lean
principles, along with the results.
3. Proof of having mentored another Lean practitioner
Gold level
1. Written exam based on recommended reading; open book (3 hours, 150 questions)
2. Submission and evaluation of an experience portfolio. Must provide documentation of
leadership in an ongoing lean transformation. Must also show record of having led 4
value stream transformations (Demand, Delivery, Development, Support).
3. Proof of having developed a training strategy and delivery for other lean practitioners.
COST:
List price
SME/AME member or
Shingo Prize examiner
Prior Bronze Certified
SME/AME member or
Shingo Prize examiner
Prior Bronze Certified
Non-member
Prior Silver Certified
SME/AME member or
Shingo Prize examiner
Prior Silver Certified
Non-member
BRONZE
$690.00
SILVER
$1,330.00
GOLD
$1,970.00
-35%
-35%
-43%
$448.50
$864.50
$1,142.60
---
-60%
-43%
$532.00
$886.50
---
-35%
-25%
$864.50
$1,477.50
---
---
$591.00
---
---
$886.50
-70%
-55%
PROGRAM LINK:
http://www.sme.org/cgi-bin/certhtml.pl?/cert/lean_certification.htm&&SME&
BROCHURE:
http://www.sme.org/downloads/cert/lean/lean_brochure.pdf
PRODUCTIVITY INC.: LEAN MANAGER CERTIFICATION
LOCATION:
Fisher College of Business at The Ohio State University, USA.
CERTIFICATES/CERTIFICATION OFFERED:
Lean Manager Certification
TARGET PARTICIPANT/PROGRAM GOAL:
From the program website: THE LEAN MANAGER CERTIFICATION IS designed for middle and toplevel executives at any company who seek the essential knowledge necessary to drive Lean
throughout their entire organization. Over four non-consecutive weeks, each participant
will experience a series of learning modules focusing on the four key phases of Lean
implementation: Plan, Pilot, Deploy and Integrate. In between the weeks of training,
students need to apply the methods that they have learned in operations at their own
companies and present their results to the class.
Upon completion, participants should be able to:
- Perform as a principal change agent
- Lead and direct site teams in completing plant-wide deployment of Lean methodologies
- Mentor and coach project leaders, managers, and supervisors in specific tools/methods
- Mentor and coach suppliers' change agents to address quality/delivery problems
CONTENT COVERED:
Week 1: Plan
Strategic Thinking; Organizational Innovation; Value Stream Management and Analysis
Planning & Deployment; Project Management; Six Sigma (DMAIC, SIPOC, CEDAC); Project
Chartering, Week in Review, Exam & Homework
Week 2: Pilot
Homework Projects; Total Productive Maintenance; Visual Workplace; Standard Work;
Quick Changeover; Mistake Proofing; Plant Application; Project Roundtable, Week in
Review, Exam & Homework
Week 3: Deploy
Homework Reports; Kanban; Pull Production; Homework Reports; Continuous Flow; Plant
Application; 3P (Pre-Production Planning); Green in the Workplace; Lean Measurables
Review, Exam & Homework, Assignments
Week 4: Integrate
Lean Logistics; Lean Supply Chain; Lean Finance; Lean Leadership; Final Project Reports;
Manager, Supervisor Role & Responsibilities; 4 Week Program Recap, Final Exam,
Graduation Dinner
INSTRUCTION/LEARNING METHOD:
During week-long instructions sessions:
Lecture/workshop
Simulations
During weeks between instructions sessions:
Homework assignments including: “gathering and analyzing information to facilitate
planning for your transformation process, selecting an initial application (pilot) area,
completing your current state value stream map, designing manufacturing cells, and
implementing Kanban pull systems.
PRE-REQUISITE(S):
It is required that each participant in the program have a corporate sponsor to attest to the
participant's qualification for the program and to the results achieved through the
homework assignments.
CERTIFICATION REQUIREMENTS/ASSESSMENT(S):
1.
2.
3.
4.
Successful completion of the four-week training
Successful completion of the mentoring program
Must pass a two-hour certification exam
Must demonstrate successful implementation in one’s own facility
COST:
Lean Enterprise Certification
Duration
20 days
Price
$15,000
PROGRAM LINK:
http://www.productivityinc.com/certification/mac.shtml
BROCHURE:
http://www.productivityinc.com/pdf/LMAC_SPRING_2010_BROCHURE.pdf
INSTITUTE FOR LEAN SYSTEMS: LEAN MANAGER CERTIFICATION
LOCATION:
Louisville, Kentucky, USA and Brunswick VIC, Australia.
CERTIFICATES/CERTIFICATION OFFERED:
Lean System Certification Series
Lean Leadership Certification Series
TARGET PARTICIPANT/PROGRAM GOAL:
Lean System Certification
From the website: This series is designed for change agents and leaders responsible for
implementing your transformation strategy. The series is intellectually rigorous but is
tailored to be appropriate for all team members. CEOs, Presidents, managers, supervisors,
and team members from all departments have successfully completed this series.
Lean Leadership Certification
From the website: This series is designed to equip participants to serve as internal
consultants and coaches to sustain your continuous improvement culture. The series is
intellectually rigorous and is not appropriate for all team members. We expect that
participants will have already mastered lean operations and tools.
CONTENT COVERED:
Lean System Certification Series
Week 1 – Designing the Lean System: VSM, analysis, and design workshop. Discuss and
apply detailed practical approaches for creating flow, and explore a variety of pull systems.
Week 2 – The Lean Work System: 5S workplace organization, workstation design, visual
controls, standardized work, SMED, source quality, and pull systems.
Week 3 – Managing the Lean System: Explore the role of people in a lean system; problem
solving strategies include C4, Six Sigma, and TRIZ; Daily Management System.
Lean Leadership Certification
Week 1 – Transformation Technology: Map and redesign technical systems to support and
sustain lean operations. Apply useful analytic techniques to decide how to structure
operations, management, and control systems. Apply lean systems design principles to
transactional and internal logistics processes as well as lean auditing systems and total
equipment management. Explore the concepts of factory physics and discover how useful
these tools are for analyzing complex operations and problems.
Week 2 – Leadership the Lean Way: Explore the value and methods of developing servant
leadership in organizations; Introduction of specific strategies and techniques for coaching,
teaching, and facilitating change activities. Also: Hoshin and a related exercise.
Week 3 – The Lean Enterprise: reviews the knowledge gained through all previous
workshops and projects and requires successful application of principles, tools, techniques,
and practices in a comprehensive extended enterprise simulation.
INSTRUCTION/LEARNING METHOD:
During week-long instructions sessions:
Lecture/workshop
Simulations
During weeks between instructions sessions:
Application of concepts
PRE-REQUISITE(S):
Lean System Certification Series: [none]
Lean Leadership Certification Series: demonstrated prior Lean knowledge/ability
CERTIFICATION REQUIREMENTS/ASSESSMENT(S):
1. Successful completion of the three-week training
2. Must complete two transformation projects with support from their management
COST:
Lean System Certification Series
Lean Leadership Certification Series
PROGRAM LINK:
http://www.theleanway.com/services_certification.html
Duration Price
15 days
$7500
15 days
$7500
TBM CONSULTING GROUP: LEAN AND LEAN SIGMA CERTIFICATION
LOCATION:
Durham, North Carolina, USA and others including Brazil, China, Mexico and the UK
CERTIFICATES/CERTIFICATION OFFERED:
Lean Certification: Kaizen Facilitator
Lean Certification: Program Leader
Lean Sigma Green Belt, Lean Sigma Black Belt
TARGET PARTICIPANT/PROGRAM GOAL:
Lean Certification: Kaizen Facilitator: Appropriate for candidates who want to learn how to
lead kaizen events. By completion, a participant will have:
- Knowledge of lean strategies, tools and methods which include the fundamentals of the
Toyota Production System including takt, flow, pull and standard operations
- The skills required to support kaizen events and conduct basic training for kaizen teams
- Participation in a kaizen event in a process at a manufacturing facility
- Develop a current and future value stream map for a facility or product family
Lean Certification - Program Leader: Appropriate for lean practitioners and program
managers responsible for leading lean deployments or multi-site continuous improvement
objectives. Graduates complete the program with hands-on experience and knowledge to
develop a lean transformation plan for a site, division or company. In addition to the goals
listed for Kaizen Facilitator, a Program Leader will also know:
- How to create, manage, communicate and promote a continuous improvement office
- How to write a project charter, develop scope and objectives for a kaizen event
- How to align operations metrics with financial performance
- How to audit, report and sustain results from your lean deployment
CONTENT COVERED:
Lean Certification: Kaizen Facilitator and Lean Certification: Program Leader
Essential Lean Learning – Online training and Exam (self paced online learning)
Modules include: Introduction to lean; Waste elimination; Just-in-time principles of takt,
flow and pull systems; Quality and productivity improvements through Jidoka; Production
Smoothing, Standard Work, Standard Operations; 5S and the visual workplace; Value Chain
Mapping, LeanSigma Implementation; and Roles in a lean deployment.
Lean Tool Kit Workshop (5 days)
Learn how lean tools are applied to transform your organization to deliver improved
operational results. Through the use of a factory simulation students will be able to apply
what they have learned.
Kaizen Breakthrough Experience (5 days onsite at a TBM client location)
Participants are divided into teams that are led by a TBM Lean Master. Team members are
assigned roles; the event is planned, executed and evaluated.
Kaizen Instructor Training (4 days)
Train-the-trainer workshop to demonstrate how to deliver TBM’s one-day lean training and
address the questions from participants in or impacted by a Kaizen event.
Additional requirements for Lean Certification: Program Leader Creating a Continuous Improvement Office (4 days)
Strategies, tools and skills required to set up an effective continuous improvement office;
includes: communication, promotion, charter statements, operational metrics with financial
objectives, lean progression assessment, and sharing best practices across the organization
Sustaining Lean Results (5 days)
How to audit, report and sustain kaizen results; Personality assessment, cultural change,
dealing with resistance, performance measurement, layered audits and problem solving
INSTRUCTION/LEARNING METHOD:
Lecture/workshop
Simulations
Onsite Kaizen improvement project with a client company
TBM Lean Mentor assigned to each participant to guide throughout process
PRE-REQUISITE(S):
Lean Certification: Kaizen Facilitator and Lean Certification: Program Leader
Must have the ability to travel in order to complete improvement workshop module
CERTIFICATION REQUIREMENTS/ASSESSMENT(S):
1. Successful completion of all course work and site visits
COST:
Lean Certification: Kaizen Facilitator
Lean Certification: Program Leader
PROGRAM LINK:
http://www.tbmcg.com/training-services/certification.html
Duration Price
14 days
$8,500
23 days
$12,500
UNIVERSITY OF MICHIGAN: LEAN CERTIFICATION
LOCATION:
Ann Arbor, Michigan, USA. Remote/onsite training also available.
CERTIFICATES/CERTIFICATION OFFERED:
Lean Manufacturing Certification – 10 days (outlined below)
Lean Healthcare Certification – 5 days (outlined below)
Lean Office Certification – 5 days
Lean Product Development Certification – 5 days
Lean Supply Chain for Healthcare Certification – 4.5 days
Lean Pharmaceutical Certification – 3 days
Lean Supply Chain and Warehouse Management Certification – 10 days
TARGET PARTICIPANT/PROGRAM GOAL:
Prior Lean experience is not explicitly listed as a requirement. Content focus is geared
towards the specific industries, as outline by title. Within each program, the recommended
attendees list essentially spans all employees within an organization.
CONTENT COVERED:
NOTE: Given the quantity of Certification programs offered, two programs were chosen for
illustration. They represent one of the 10 day programs, and one of the 5 day programs.
Lean Manufacturing Certification
This program provides multiple course configurations, selected from the complete list of single day
courses listed below. Only one configuration is given per 2-week block of time. Participants select
from the pre-configured options, instead of selecting each unit separately.
Overview: (all required)
History; Philosophy; Core methodologies
Lean System Design: (at least 3 required)
VSM: Current & Future State mapping; Design of Pull
Mechanics of Pull systems: Kanban; Analytical tools to determine inventory
Factory Layout for Lean Manufacturing: Basic Models; Practical solution methods
The Physics of Lean: Throughput; Cycle times; Customer Service; Quality; Flexibility
Build to Order: Supplier involvement; Material control systems; Logistic systems design
Supporting Lean Tools and Methods: (at least 2 required)
Cell Analysis and Design: Cell layout; Allocating work; Right-sizing equipment
Implementing Kaizen Bursts: systems around tools; VSM into action; JIT & built-in-quality
Learning to Levelize w/ Pull Systems: Mechanics of pull; Kanban; Container size; simulations
Material Handling for Lean: Evaluate parameter impact; modeling; train the trainer
Designing Std. Work and Job Instruction Training: Methods; Training tips; work break-down
Lean Rapid Plant Assessment: learn to quickly assess a plant, its value & potential
Leadership and team Management Tools and Methods: (at least 2 required)
Integrating Six Sigma in lean: Integration; employees as problem solvers; DMAIC
Leading the Change to Lean: Optimizing the system; Tools and methods
Accounting and Measurements for Lean: alternative systems; Encouraging behavior
Developing and Leading Work Groups: Fostering team work; Motivating problem solving
Lean Healthcare Certification
Day 1: Overview of Lean Healthcare and Lean Healthcare Simulation
Day 2: Value Stream Mapping Healthcare Applications; UM Hospital case study
Day 3: Toyota Practical Problem Solving and A3 Tools; UM Hospital case study
Day 4: Lean Tools for Healthcare: 5S, visual management, standardized work, Andon
systems, quick changeover, etc.; Lean healthcare case studies; hands-on exercises
Day 5: Lean Leadership and Change Management; healthcare case study; Physicians
panel/discussion
INSTRUCTION/LEARNING METHOD:
Lecture/workshop
Simulations
Discussion panels (ex: Physicians already working in a Lean healthcare environment)
PRE-REQUISITE(S):
[None]
CERTIFICATION REQUIREMENTS/ASSESSMENT(S):
Web-based exams - Manufacturing, Office and Supply Chain and Warehouse Management
[none listed] - Healthcare, Product Development, Supply Chain for Healthcare and
Pharmaceutical Certification.
COST:
Lean Manufacturing Certification
Lean Healthcare Certification
Lean Office Certification
Lean Product Development Certification
Lean Supply Chain for Healthcare Certification
Lean Pharmaceutical Certification
Lean Supply Chain and Warehouse Management Certification
Duration
10 days
5 days
5 days
5 days
4.5 days
3 days
10 days
Price
$6,495.00
$3,450.00
$2,950.00
$2,950.00
$3,450.00
$2,295.00
$6,450.00
PROGRAM LINK:
http://interpro.engin.umich.edu/Lean.htm
BROCHURES:
Manufacturing: http://confluence.engin.umich.edu/download/attachments/3958/leanManufacturing121109Web.pdf
Healthcare: http://confluence.engin.umich.edu/download/attachments/3958/leanhealthcare.pdf
Office: http://confluence.engin.umich.edu/download/attachments/3958/leanBusiness111108Web.pdf
Product Development: http://confluence.engin.umich.edu/download/attachments/3958/LeanProductProcess2.pdf
Supply Chain for Healthcare: http://confluence.engin.umich.edu/download/attachments/3958/LeanLogisticsHealthcareMainBrochure.pdf
Pharmaceutical: http://confluence.engin.umich.edu/download/attachments/3958/leanpharma91508.pdf
Supply Chain and Warehouse Mgmt: http://confluence.engin.umich.edu/download/attachments/3958/leanlogistics10808Web.pdf
UNIVERSITY OF NEBRASKA OMAHA: LEAN ENTERPRISE CERTIFICATION
LOCATION:
Omaha, Nebraska, USA. Remote/onsite training also available.
CERTIFICATES/CERTIFICATION OFFERED:
Lean Enterprise Certification
CONTENT COVERED:
Principles of Lean Manufacturing – Overview of Lean principles; Lecture and live
simulation to show how Lean improves quality, reduces costs, and increases productivity
Five S Workplace Organization - Five Pillars of the Visual Workplace and Five S
Set-up Reduction / Quick Changeover - Fundamental principles of set-up reduction;
Standard methodology in applying SMED to any industry and environment.
Value Stream Mapping - Two-day workshop; current and future state maps created for
participants’ own company's value stream.
Cellular Flow Manufacturing - Link and balance manufacturing operations; MEP five-step
process for designing and implementing work cells; Kanban and Pull methodology
Standardized Work - How to analyze the interaction of people, materials, methods, and
machines in a work process and develop the most effective combination of resources in the
best sequence to achieve the desired output and reduce waste.
Note: The Nebraska Business Development Center is the exclusive NIST/MEP-Certified Lean
manufacturing service provider in the state. They use the methods and content established by
NIST/MEP for the instruction of the program.
TARGET PARTICIPANT/PROGRAM GOAL:
Prior Lean experience is not explicitly listed as a requirement. Content focus is geared
towards the specific industries, as outlined by title. Within each program, the
recommended attendees list essentially spans all employees within an organization.
INSTRUCTION/LEARNING METHOD:
Lecture/workshop
Simulations
PRE-REQUISITE(S):
[None]
CERTIFICATION REQUIREMENTS/ASSESSMENT(S):
1. Must complete all 56 hours of course instruction
2. No formal examination listed
COST:
Lean Enterprise Certification
PROGRAM LINK:
http://nbdc.unomaha.edu/lean/leancertificate.cfm
Duration
8 days
Price
$1,700
UNIVERSITY OF KENTUCKY: LEAN SYSTEMS CERTIFICATION
LOCATION:
Lexington, Kentucky, USA
CERTIFICATES/CERTIFICATION OFFERED:
Lean Systems Certification
TARGET PARTICIPANT/PROGRAM GOAL:
From the website: The University of Kentucky Lean Certification Program starts the
development of your own internal support facilitators for the lean transformation process.
Begun in the early 90’s, this “Train the Trainer” program has become known worldwide and
has helped hundreds of companies nationally and internationally. Unlike other training
programs, the University of Kentucky certification program is not a “Lean Champion” or
“Lean Expert” program. Instead University of Kentucky is guided by Toyota’s belief that
there is no such thing as a “kaizen specialist” or a “lean expert.”
CONTENT COVERED:
Week 1: Developing the Kaizen Mind for Leadership
- Compare traditional versus lean thinking/culture
- Describe the transformational image
- List the organizational roles required for lean that sustains development
- List “true lean” principles and behaviors
- List the failure modes of lean
- Practice Toyota’s techniques for process and flow study
- Practice Toyota’s 8-Step Problem Solving methodology
Week 2: Installing the Toyota Operations Development Group
- Complete panel review of Week 1’s homework assignment
- Evaluate the transformational image
- Apply Toyota’s management improvement process named Jishuken
- Describe Toyota’s learning process
- Strengthen Process and Flow study
- Strengthen Problem Solving skill
Week 3: Maintaining Lean Through Standardization
- Complete panel review of Week 2’s homework assignment
- Apply the standardization principle
- Apply Toyota’s annual strategic planning process called Hoshin Kanri
- Describe transformational leadership
- Apply Toyota’s Production Planning process called heijunka
- Strengthen Problem Solving skill
- Strengthen role understanding
INSTRUCTION/LEARNING METHOD:
Lecture/workshop
Simulations
Homework including application of ideas at one’s own work location
PRE-REQUISITE(S):
[none listed]
CERTIFICATION REQUIREMENTS/ASSESSMENT(S):
1. Successful completion of all course work and homework
2. Attendance through all sessions
COST:
Lean Systems Certification
PROGRAM LINK:
http://www.mfg.uky.edu/lean/certification.html
Duration Price
15 days
$7,500