Lean is a business strategy to be more competitive and succesfull in your business, by improving (continuously) the way how operations are organised, involving everyone in the organization. You will learn about this approach and acquire the necessary knowlegde and skills to succesfully implement this strategy.
Green/Black Belt in LEAN
in samenwerking met P&M
This is the most in-depth and broadest Lean training and certification program in Belgium and the Netherlands, not only covering the basics of Lean but also the advanced tools and techniques for complex value stream design.
This program started in 2005, the first 6 editions were organized in collaboration with the Department of Continuing Education (IVPV) of Ghent University (Belgium). Currently this program runs once per year in Belgium with active contributions of experts from Toyota, Volvo Cars, Mars Food, Johnson&Johnson (Jansen Pharmaceutica), Alpro and others.
What is unique about this course?
There is a great demand for a thorough and in-depth training with more advanced lean techniques treated. We developed and use several hands-on simulation games and case studies for a better practical learning experience of these advanced techniques. We will cover both the 'technical' as well as the 'cultural' side of Lean. All instructors belong to organizations that have extensive experience with the implementation of lean worldwide.
MODULE 1 - Lean introduction & basic techniques (Green Belt)
This module provides a basic knowledge about Lean, both production and non-production environments.
What is Lean? Basic Principles of Lean (with a simulation game).
Value vs. 'waste' (E 'waste'), the various types of waste.
Overview of the main pillars of Lean and the main tools to implement Lean in your organization based on the Toyota Production System (TPS).
Basic Training Value Stream Mapping (VSM): mapping the value flows from raw material to customer delivery. Create a roadmap for improvement from a future state, designed on the basis of eight Lean design guidelines for flow.
Operational stability as the foundation: standard work, 5S workplace organization, improving the reliability of your technical equipment with TPM.
Basic continuous improvement techniques (Kaizen, PDCA, A3, 5xWhy, ...).
Kanban / Pull systems: what are 'pull' systems? Overview of the different implementation forms (with hands-on mixed model Kanban simulation game).
Reduction of change over times with SMED (Single Minute Exchange of Dies): Flexibility is essential in Lean. Short change over times are therefore a must!
The Jidoka pillar (built in quality "): Quality from a Lean perspective, but not so much inspection, and Poka Yoke, Andon, autonomation and visual management.
Translate the TPS approach towards non-production environments (administration, service delivery and support processes). What are the differences?
Business Process Value Stream Mapping (BPVSM): Mapping service and transactional processes, and develop an implementation plan for more flow, based on an 8-steps plan.
MODULE 2 - Advanced Lean techniques
The basic concepts are introduced in Module 1 and are further explored here in more complex situations with more advanced techniques to improve flow in your organization. We treat a.o.
Mixed Model Value Stream Design: Common product families consist of a large list of products, with different cycle times, setup times, etc. How to improve the flow in the value stream such a situation?
Flow in value streams with many 'Shared Resources' (ressources which are shared between different product families).
How to design and improve flow in the supporting, internal logistics value streams
Design for Flow: preventing waste by incorporating Value Stream Flow Design thinking and principles during the engineering phase.
Lean at Supply Chain level: how to connect different plants and warehouses, at different/distant locations with improved material and information flow based on Macro (Extended) VSM and Lean Design principles.
Additional tools to further reduce and eliminate the waste in office/service environments: Overhead Value Analysis, Contactograms, Written Communication Analysis, Meeting Structure Analysis, Factor Variable Programming (VFP), approaches to deal with variability.
Work Sampling (NL: Multi Moment opnames - MMO): excellent technique for quantifying waste and your improvement potential in environments where people have a variable or unpredictable work content.
A hands-on simulation game of a service/office environment involving multiple value streams (including the problem of "shared resources" in these environments) to learn the use of Business Process Value Stream Mapping and its Lean Design for Flow principles in practice.
MODULE 3 - Six Sigma tools to support Lean
Participants who are already certified as Black Belts in Six Sigma are exempt from taking this module while pursuing the Black Belt in Lean certificate. Where Lean initially focuses on eliminating waste and non value added activities in the value stream and improving , with the Six Sigma techniques you try to reduce variation and thus improve the controllability of the value added stepse. Six Sigma can therefore fit perfectly in a Lean context. In this module, the Six Sigma roadmap for executing improvement initiatives (DMAIC) and a selection of basic tools and techniques are discussed. A number of guided exercises in MS Excel to show how the most basic analyzes with this well known software can be executed.
MODULE 4 - Create a Lean organisation
"The soft stuff is the hard stuff", even with a Lean implementation. Lean is more than the implementation of tools and techniques. As a business strategy lean is only effective if the Lean principles and values in the culture of the organization are anchored, at all levels, not only in "Operations", but also with all supporting departments. In this final module, we focus on the human factor. Hoshin Kanri (policy deployment), communication and dealing with change, A3 thinking, standard work for (daily) management and improvement (the 'Operating System') and Human Resources Development (HRD) are discussed, illustrated with testimonials. Finally, we will also discuss the impact of Lean on accounting and cost calculation in order to make the impact of flow improvement financially quantifiable. The traditional accounting and costing techniques are typically not able to show the (short term) financial benefits of flow improvements and the impact on the cash flow. Often the financial indicators even seem to be worse, which leads to taking wrong operational and engineering decisions. An effective alternative is to develop cost models at the value stream level, based on Throughput Accounting, in order to clearly show the financial impact of Lean. Hence, we conclude this module with a session on Value Stream Costing and Accounting for Lean.
The Lean Champion and Black Belt in Lean participants will have the opportunity to join us for one or more company visits to see how Lean is implemented in practice.
The entire Black Belt in Lean training is completed with a Lean implementation case. The participant can thus demonstrate that he / she has acquired sufficient and in-depth knowledge of the subject matter to independently and successfully apply this in their own work environment. So there is even a direct return on investment realized for the organization. During this phase, the participant also has an opportunity to ask for one interim feedback/coaching moment. Finally a written report will be submitted that will be reviewed and defended before a jury of Lean specialists.
|1 (Green Belt)||€ 3.175|
|1-4 (Black Belt)||€ 7.845|
|2-4 (only Black Belt)||€ 5.513|
|1, 4 (Champion)||€ 5.247|
|Please mention for which module you register: Green, Black, only Black or Champion|
KMO-portefeuille: vraag hier uw subsidie aan en bespaar tot 40% op uw inschrijvingsprijs.
Erkenningsnummer Allanta: DV.O105117
prices are exam + certificate inclusive
Uw opleiding in detail
None for the Green Belt module/certification, a Green Belt certificate or succesfully pass the theory part of the Green Belt certification for the Black Belt/Lean Champion modules/certification.
Participants that have taken (open or in-house) Lean classes with us before, can get exemptions (and a reduced registration fee). Contact us for more details. There are no exemptions with regard to the exams.
This training is intended for operations managers, process engineers, method engineers, team leaders, everyone who is committed to continuous improvement in manufacturing, office or service environment. The number of participants for the Green Belt, Lean Champion as intensive Black Belt training is limited to guarantee a high interactivity of the sessions and games.
Students who follow all modules, succeed in the Green and the Black Belt theory test, develop a lean implementation case independently and successfully, defend it before a jury of lean experts, receive the "Black Belt in Lean" certificate.
The label Black Belt (mainly known from Six Sigma) ensures a knowledge and skill level to be able to lead a lean implementation on value stream level within the organization. The Black Belt further can instruct and coach team members and take the lead in the implementation.
It is sufficient to follow the firs module module. The certificate "Green Belt Lean” is obtained after passing a theory test and a written report of at least one succesfull practical application (Kaizen) with actual result of the lean basic tools that are presented during this module.
The student in this case has acquired sufficient knowledge in Lean to apply and coach the implementation of the basic techniques of Lean. He can be part of improvement teams and even lead or coach such a kaizen team.
To support a lean implementation in a management/executive role, one must understand the basic philosophy of lean, the basic tools and the supporting elements to create a lean culture. This is achieved by taking the classes of modules 1 and 4. The certificate Lean Champion is hereby awarded after passing the Green Belt theory test and a successful preparation of a strategic lean implementation plan in your own work environment.
TEL +32 (0) 11 870 944
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