Curriculum

Get Your Company Closer to Lean at Internet Speed

Twelve Modules of Introductory Lean Training for the Entire Enterprise

The online training modules of our Essential Lean Learning curriculum are suggested learning for all associates who support and participate in a lean transformation. Students learn through reading, narration, and a series of simulations and exercises designed specifically for adult learners.

Upon completion, expect associates to be familiar with lean terminology and concepts. They should have some basic experience applying their knowledge and have a better understanding of their role in your lean transformation.

The curriculum consists of 12 modules taken in progressive order. Each module begins with a summary of what's covered and closes with a 10-question quiz designed to test for comprehension of core learning deliverables. Plan 30-50 minutes of learning time per module.

Who should participate?

Leadership and management teams, shop floor associates, team leaders and supervisors
Associates in production, engineering, quality, materials management, distribution, business process, sales, marketing and other administrative functions who participate in or support your continuous improvement initiative
Suppliers and customers

TBM Online Learning: New Essential Lean Learning Curriculum

Curriculum for Essential Lean Learning
Course Name	Course Description
100: Introduction to the LeanSigma Journey	Understand what's required to begin your lean transformation. Become familiar with the major objectives of lean and fully understand why you are embarking on a lean journey.
101: LeanSigma Overview & Time-Based Strategy	Understand how LeanSigma is a business strategy for growth and profitability - and how lean is a process for identifying and eliminating waste and unreasonable activities. Differentiate Lean from Six Sigma. Learn how lead-time reduction will improve quality, cost and deliver performance.
102: Waste Elimination	Differentiate between value-added and non value-added activities. Understand the three criteria to qualify as value-added activity. Identify and understand the seven categories of waste. Describe why creating defects and overproduction lead to the most waste.
103: Just-in-Time Principles: Takt, Flow and Pull	Understand the concepts of takt, flow and pull. Learn to calculate takt time as the pace for customer demand. Appreciate differences between batch, fake flow and one-piece flow. Differentiate between push and pull production systems.
104: Quality Improvements through Jidoka	Understand the importance of identifying the problem and establishing a process to fix issues as they occur. Recognize the role of Jidoka to improve quality by preventing defects from being passed downstream. Explain how Jidoka improves productivity by separating operator and machine work by freeing up operator availability.
105: Production Smoothing	Define production smoothing and describe how it is used to meet rates of variation in customer demand. Understand how the was te of over production and inventory can be reduced utilizing a product mix strategy. Calculate optimal product mix by using takt time along with a product mix table.
106: Standard Operation Tools	Define cycle time. Explain why time observation is an effective method of analyzing a process to identify waste. Become familiar with tools to evaluate operator work balance within a group. Establish the number of operators required for production to meet customer demand. Define standard work in process as the minimum amount of material required to complete the work sequence on demand.
107: Improvement through Standard Operations	Understand the role and importance of standard operations. Identify four key elements of standard operations. Describe how standard work in process enables the completion of the work sequence to demand. Name the three steps to implementing standard operations.
108: Progressive 5S & the Visual Workplace	Define 5S as a process and method for creating and maintaining a safe, organized, clean, high-performance workplace. Explain that 5S creates an environment that enables standard work and aids in the identification of waste. Define the 5Ss in progressive 5S and state the key activity of each "S". Demonstrate the use of the first three Ss. Explain how to use the score sheet as a tool to improve 5S.
109: Value Chain Mapping	Define a value chain map as the visual tool for displaying the flow of information and material through a process. Become familiar with and define the key elements of a value chain map. Define the steps for creating a value chain map of your own.
110: LeanSigma Implementation	Define the kaizen breakthrough methodology as the rapid improvement of a process through the use of a cross-functional team. Identify the characteristics of an optimum kaizen team. Grasp key kaizen principles and understand how to define key objectives for each of the five days of a kaizen event.
111: Your Role in the Company's Transformation	Be able to define your role in the transformation process, identify obstacles you may encounter, explain key steps that you should take to continue and sustain a lean transformation. Understand how to make a significant difference in a company's objectives to drive growth, earnings, and its reputation as a challenging and rewarding place to work and grow.