Lean Enterprise Certification Program

Location: Tempe Arizona
Dates: Custom program for companies or groups of 15 or more
10 Day program Fee: $3,500
Individual Course Modules: $400 per course day

Program Sections:

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Overview

This noncredit professional certification program will provide critical enterprise system thinking, strategies, methods, and tools. The core focus is to develop the leadership skills necessary to successfully analyze, plan, and implement a lean/six sigma strategic plan. The program combines action learning through group discussion and exercises, case study analysis, hands-on simulations, group learning sessions and special presentations from executives who have led successful lean implementations.

Learning and Knowledge Outcomes

  • Develop the ability to recognize, design, and implement more efficient and customer-oriented value streams (manufacturing, design and administrative).
  • Understand core lean system elements such as one-piece flow, pull systems, and quality at the source and how to integrate into the value streams of a lean enterprise.
  • Analyze critical quality and delivery problems and lead redesign teams across the supply chain.
  • Optimize people, machines, materials, and facilities leading to significant improvements in quality, cost, on-time delivery, and performance.
  • Develop a detailed Lean Change Plan with measurable value-added returns.
  • Lead and direct high-performance teams to deploy enterprise wide implementation of strategic methodologies.
  • Know how to leverage process mapping, standardized systems, and other key concepts beyond the factory through collaborative process and product engineering strategies.

Who Should Attend

The program is designed to develop implementation and change leaders in the area of lean manufacturing. We encourage participation from Vice Presidents, Plant Managers, Manufacturing Engineers, Engineering Managers, Industrial Engineers, Team Leaders, Supervisors of Supply Chain Management, Quality/Six Sigma, Logistics Management, and Purchasing Management supporting the implementation of a lean manufacturing enterprise.

Program Schedule

Strategy Planning and Deployment Part 1 (1-day)

Professor Dan Shunk, Ph.D.
ASU Industrial Engineering Department

This session will expand the focus of Lean to a strategic differentiator in the 21st Century. Includes the hybrid strategies of "rapid time to market" and "compressing time" as real competitive advantages through Lean. Methodologies for Lean strategic planning and deployment will be developed and include exercises to allow participants to master the approaches in the classroom.

  • Strategy Plan Development
  • Lean Enterprise Assessment Overview
  • Self Assessment: Analyze the Current State
  • Gap Analysis and Strategic Deployment
  • Analyzing and Understanding Data
  • Enterprise Strategic Deployment Plan Development

Value Stream Mapping and Design (2-days)

Jim Strickland, Industrial Affiliate Instructor,
ASU Center for Professional Development

Jim is currently the Lean Enterprise Manager and Six Sigma Champion for Raytheon Missile Systems in Tucson, AZ. He has spent his last 36 years in all areas of Manufacturing Operations. He has led Tucson's transition from traditional manufacturing to an award winning (Pioneer Award, Industry Weeks "Best Plant", 2004 Shingo Prize) Lean environment that it enjoys today. Jim helped create the Raytheon Production System and led the team that revolutionized Tucson's manufacturing processes. He also helped develop and led the R6S (Raytheon Six Sigma) activities which are recognized nationally as one the best models for the "melding of Change Management, Lean, and 6Sigma in the country". Jim has managed projects in Europe, South America, and in numerous states across the country. In his current role, he is responsible for helping a 3,300-employee organization to drive improvement to the "next level". This leadership module will present an Aerospace Industry "best practice" model and help the students create a leadership model for their organizations. Through a series of interactive games, presentations, and brainstorming sessions, the students can lead their own "roadmap" to Lean success.

This 2 day Module:

Lean is a system of production and requires a plan for the whole system. Value stream mapping is a methodology for mapping the current flow of product and information through your operations and developing a future state vision of a lean flow from dock-to-dock and beyond. Value stream mapping is based on a methodology developed by Toyota and enhanced by Mike Rother and John Shook in Learning to See. This book has received national acclaim as a guide to lean transformations and was awarded the prestigious 1999 Shingo Prize for Excellence in Manufacturing Research and will be used as the course text.

  • What is the value stream and value stream mapping
  • Concepts of material and information flow
  • Drawing a current state map
  • Characteristics of a future state value stream
  • Visioning and drawing a future state value stream

Creating Continuous Flow

Jim Strickland, Industrial Affiliate Instructor,
ASU Center for Professional Development

This module provides practical Toyota-based thinking, methods, and tools for designing, implementing, and continuously improving operator based continuous flow cells and lines. The focus is on a value stream's pacemaker process-typically assembly- although the methods are applied in any operator based process where you intend to develop true continuous flow production.

Integration of Lean and Six Sigma Methodologies and Strategies

Professor Doug Montgomery, Ph.D.
ASU Industrial Engineering Department

Lean Flow is a natural complement to Six Sigma. The data gathered in your lean flow implementation will help identify your highest impact Six Sigma opportunities, and every process improvement made with Six Sigma will make it easier and cost effective to achieve optimum flow.

  • Overview of Six Sigma thinking
  • DMAIC
  • Integration of Lean and Six Sigma thinking
  • Developing Lean/Six Sigma Teams
  • Organizing and Leading Change Initiatives

Second Session
Strategy Planning and Deployment (Part 2)

Professor Dan Shunk, Ph.D.,
ASU Industrial Engineering Department

Students will present their Lean Enterprise Assessment data they have analyzed during the one-month break. Here, they will present a preliminary "Strategic Plan" to facilitate improvements across the enterprise and to share with leadership in their companies. Faculty and student peers will provide input and recommendations to revise and refine these enterprise plans.

Industry Benchmark Case Studies (afternoon)

Presentations by industry speaker

Factory Physics

Professors John Fowler, Esma Gel, Stephen Brown
ASU Industrial Engineering Department

Today's manufacturing plants can be evaluated in a number of ways, giving rise to a set of commonly used performance measures. Understanding how factories operate, how performance is measured, and how operational changes impact performance metrics is critical in the modern factory. These measures are an indication of how well a factory is operating with respect to given criteria. For example, a factory can be judged by how much finished product it manufactures in a given time period. This performance measure is called throughput and a manufacturer wants high throughput. However, throughput depends on a variety of factors - ranging from production capacity, to work-in-process inventory, to process variability. Understanding these complex relationships can be key to improving factory performance in the lean enterprise.

Advanced Factory Physics

Professor John Fowler,
ASU Industrial Engineering Department

This course builds upon the skills learned in the Factory Physics course and focuses upon taking what you have learned and developing workable solutions. Specific topics will be shop floor control, push vs. pull manufacturing, production scheduling, workforce planning, inventory management, and how manufacturing within a given facility affects the supply network. Hands-on exercises will allow the participants to better understand the synergistic nature of these topics.

Leading the Lean/Six Sigma Organization:
Sustaining Ongoing Quantum Performance

Jim Strickland, Industrial Affiliate Instructor,
ASU Center for Professional Development

Jim is currently the Lean Enterprise Manager and Six Sigma Champion for Raytheon Missile Systems in Tucson, AZ. He has spent his last 36 years in all areas of Manufacturing Operations. He has led Tucson's transition from traditional manufacturing to an award winning (Pioneer Award, Industry Weeks "Best Plant", 2004 Shingo Prize) Lean environment that it enjoys today. Jim helped create the Raytheon Production System and led the team that revolutionized Tucson's manufacturing processes. He also helped develop and led the R6S (Raytheon Six Sigma) activities which are recognized nationally as one the best models for the "melding of Change Management, Lean, and 6Sigma in the country". Jim has managed projects in Europe, South America, and in numerous states across the country. In his current role, he is responsible for helping a 3,300-employee organization to drive improvement to the "next level". This leadership module will present an Aerospace Industry "best practice" model and help the students create a leadership model for their organizations. Through a series of interactive games, presentations, and brainstorming sessions, the students can lead their own "roadmap" to Lean success.

  • Appreciate the roles of 6Sigma "black belts" in a Lean environment.
  • Understand how to lead rapid change in a Manufacturing environment.
  • Learn how to create a Lean Six Sigma Enterprise roadmap to success.
  • Understand the impact of common tools and metrics.

Fee Schedule

  • 10-day Program Fee: $3,500
  • Individual Course Module Fee (1-day): $400/each

Registration

Refunds and Cancellations

Should you register and then need to cancel, please note that there is a cancellation fee. The rate of the fee is determined by how far in advance of the program/module start date the written request for cancellation is received by the Center for Professional Development and Distance Education (please see below). Written requests for cancellation may be received via either mail or fax.

  • Within two weeks - 50% of program fee
  • Once program starts - no refund

Transfer to another program or module is subject to a $250 administrative fee if made within six weeks of the program/module start date. Registrants who do not attend and do not cancel are subject to the complete fee. Participant substitutes may be made by submitting in advance a written request. The Center reserves the right to change instructors or cancel or reschedule a program in the event of insufficient enrollment or unforeseen circumstances.

For more information contact:

Octavio Heredia
Associate Director, Extended Education
asu.cpd@asu.edu