Lean Master Training Requirements

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Hugh Lambert
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1 Lean Master Training Requirements The following requirements are in addition to Juran Lean Expert Certification. There are five phases of an LVSM project: 1. Define Value 2. Measure Value 3. Analyze Process Flow 4. Improve Process Pull 5. Control Process For EACH phase the Lean Master Candidate must complete: Define Value Measure Value Analyze Process- Flow Improve Process- Pull Control Process Reading Assignments: Part 1 X X X X X Case Examples: Part 2 X X X X X Literature Review: Part 3 X X X X X 1

2 Part 1: Reading Assignments Reading assignments listed for each phase of the LVSM methodology are taken from the reference books listed below: 1. Automotive Industry Action Group (rev. 2001) Potential Failure Mode and Effects Analysis (FMEA). 2. Hirano, Hiroyuki and Bruce Talbot (translator) (1995) 5 Pillars of the Visual Workplace: The Sourcebook for 5S Implementation, Productivity Press, Portland, Oregon. 3. Handbook, Fifth Edition, McGraw-Hill, New York, New 4. Monroe, D. Analyzing Value Streams, Quality Magazine, January, 2006, pp Rother, M. and J. Shook (1999) Learning To See: Value Stream Mapping to Create Value and Eliminate Muda (Edition 1.2), Lean Enterprise Institute, Brookline Massachusetts. 6. Tapping, D., T. Luyster, and T. Shuker (2003), Value Stream Management: Eight Steps to 7. Womack, James P. and Daniel T. Jones (2003) Lean Thinking: Banish Waste and Create Wealth in Your Corporation (Revised and Updated), Free Press, Simon & Shuster, New York, New Part 1 Deliverables: For EACH reading assignment the Lean Master Candidate must list three to five key points. For example, Takt Time Calculation and how and when this concept or tool could be applied in your company to strengthen the Lean program. The Lean Master Candidate must submit the reading assignments for review to the Juran Mentor. The Juran Mentor will question the candidate about specific important points. The Lean Master candidate should prepare and submit questions or points for further clarification or explanation. For example, "How would you apply a process FMEA to a purely transactional case such as purchasing?" 2

3 DEFINE VALUE READING ASSIGNMENTS (DEF01 through DEF08) Handbook, Fifth Edition, McGraw-Hill, New York, New A. DEF01: How to Think about Quality: Section 2 B. DEF02: The Quality Planning Process: Section 3 C. DEF03: Quality and Income: Section 7 D. DEF04: Quality and Costs: Section 8 E. DEF05: Strategic Deployment: Section 13 F. DEF06: Project Management: Section 17 A. DEF07: Step 1: Commit to Lean B. DEF08: Step 2: Choose the Value Stream MEASURE VALUE READING ASSIGNMENTS (MEA01 through MEA07) Handbook, Fifth Edition, McGraw-Hill, New York, New A. MEA01 Measurement, Information and Decision-Making: Section 9 B. MEA02 Inspection and Tests: Section 23 C. MEA03 Basic Statistical Methods: Section 44 Rother, M. and J. Shook (1998) Learning To See: Value Stream Mapping to Create Value and Eliminate Muda, Lean Enterprise Institute, Brookline Massachusetts. A. MEA04 Getting Started: Part I B. MEA05 The Current State Map: Part II Monroe, D. Analyzing Value Streams, Quality Magazine, January, 2006, pp A. MEA06 Entire Article A. MEA07 Step 3: Learn About Lean 3

4 ANALYZE PROCESS-FLOW READING ASSIGNMENTS (ANA01 through ANA03) A. ANA01 Pp : Stage Two: Focus on Flow Automotive Industry Action Group (rev. 2001) Potential Failure Mode and Effects Analysis (FMEA). A. ANA02 Process FMEA Handbook, Fifth Edition, McGraw-Hill, New York, New A. ANA03 Section 6: Process Management IMPROVE PROCESS-PULL READING ASSIGNMENTS (IMP01 through IMP08) Womack, James P. and Daniel T. Jones (2003) Lean Thinking: Banish Waste and Create Wealth in Your Corporation (Revised and Updated), Free Press, Simon & Shuster, New York, New A. IMP01 Lean Principles: Part I B. IMP02 From Thinking to Action- The Lean Lean; Part II Rother, M. and J. Shook (1998) Learning To See: Value Stream Mapping to Create Value and Eliminate Muda, Lean Enterprise Institute, Brookline Massachusetts. A. IMP03 What Makes a Value Stream Lean?: Part III B. IMP04 Future State Map: Part IV C. IMP05 Achieving the Future State; Part V A. IMP06 Pp : Stage Three: Focus on Leveling B. IMP07 Step 7: Create Kaizen Plans C. IMP08 Step 8: Implement Kaizen Plans 4

5 CONTROL PROCESS READING ASSIGNMENTS (CON01 through CON03) Handbook, Fifth Edition, McGraw-Hill, New York, New A. CON01 The Quality Control Process: Section 4 B. CON02 Operations: Section 22 Hirano, Hiroyuki and Bruce Talbot (translator) (1995) 5 Pillars of the Visual Workplace: The Sourcebook for 5S Implementation, Productivity Press, Portland, Oregon A. CON03 Chapters 1-4 Part 2: Case Study Exercises For EACH phase, prepare a non-confidential case example suitable for use as a classroom exercise of one of the major tools of the phase. This is reviewed by a Juran specialist as part of the preparation for the in-depth presentation and analysis the Lean Master Candidate will present to Juran. These examples can be based on real Lean projects or constructed from real data on similar projects or published reports. Also show the type of graphs and plots that might be generated, and the conclusions made during each phase. Part 2 Deliverables: Five case examples in Minitab, MS Word, MS PowerPoint, or MS Excel with data files, graphs, charts and output. Also include, analysis files, and brief description of a problem or a project with key points identified and data-driven conclusions. Summarize notes in preparation for review with Juran and critique strengths and weaknesses of approach taken, methods used, and conclusions. Part 3: Literature Review For each LVSM phase conduct a literature review to identify two new references shedding additional insight on concepts, tools, methods, or applications for each phase. This literature search should be outside of the basic texts and articles used in Juran's Lean workshops, and preferably, of recent contributions to the field. 5

6 Part 3 Deliverables: Hard or electronic copies of ten papers (or book chapters) with marginal comments. Summarize notes in preparation for discussion (with Juran) of specific new insights on concepts, tools, methods, or applications for this phase and ideas on how these may be used in the Lean Master's company to further strengthen the Lean program. 6

Master Black Belt TRAINING REQUIREMENTS

Master Black Belt TRAINING REQUIREMENTS There are five training phases: Define, Measure, Analyze, Improve/Design, and Control/Verify. For each phase, the Master Black Belt (MBB) candidate must complete: Reading Assignments (Part One) Case Studies