Level 3 – Lean Expert Training & Certification Package

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On this page, is information about our advanced level training course, which is part of the 10 Steps to become a Lean Enterprise training and implementation series developed by Chris Turner. This training course is called “Level 3 – Lean Expert in Manufacturing.”

lean manufacturing training online

Lean Expert gives you the skills to help others understand how the pieces of the lean puzzle fit and work together!

The Level 3 – Lean Expert training course was originally designed as one hundred and sixty hours of training, which are delivered over a period of twenty business days. The Lean Expert training is separated into four weekly training sessions, each session being five consecutive business days, and is typically presented by an on-site consultant at many of our client’s premises. The Lean Expert training will allow you to develop the necessary skills to teach and help others to understand how the pieces of the lean jigsaw puzzle fit together!

When you sign up for our online version of the “Lean Expert in Manufacturing” training course, you receive the same quality step by step instruction from Chris Turner, our Lean Manufacturing Coach through a series of training videos, course workbooks and supporting materials. You will not need to purchase any additional materials, everything you need is included in the complete training package.

During the Lean Expert in Manufacturing training, you gain advanced knowledge about the implementation and integration of lean tools and techniques as described in the 10 Steps training and implementation model. We take a deeper look into the implementation process to understand the why, when, how, and how to!

This course clearly defines the required infrastructure and best practices, that are necessary to integrate the concepts from the “Level 1 – Lean Awareness in Manufacturing” training course, and the application of lean tools and techniques from the “Level 2 – Lean Practitioner in Manufacturing training course.

Please note: The Level 1 – Lean Awareness and Level 2 – Lean Practitioner training materials are included in the Level 3 – Lean Expert training package at no additional cost.

Chris Turner has 30+ years of hands-on lean experience and he will personally share his knowledge. He will give a more detailed explanation, and demonstrate how an organization can direct its process improvement team to successfully deploy lean principles into its manufacturing processes.

Lean Manufacturing Online training modules teach and demonstrate the same principles that were designed and developed in the Toyota Production System. These principles have allowed the Toyota Motor Company to become globally accepted as a World Class – Lean Manufacturing business.

Lean Expert Video

Thank you for your interest in our Level 3 – Lean Expert in Manufacturing online training course. Click on the image below to watch a short video to learn more about our Level 3 training.

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At the beginning of each training module, you will see a screen with an outline of the course objectives. To achieve the training goal for this course, you will need to actively participate in the training and fully understand each of the learning objectives. You can see a detailed list of the course objectives for the Lean Facilitator in Manufacturing below.


Level 3 – Lean Expert in Manufacturing Course Objectives:

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Step 1 Strategy Deployment.

Step 2 Value Stream Mapping.

Step 3 Workplace Organization.

Step 4 Process Flow.

Step 5 Reduce Changeover Times.

Step 6 Pull System.

Step 7 Balanced Workload.

Step 8 Standard Work.

Step 9 Continuous Improvement.

Step 10 Lean Supply Chain.

Step 1: Strategy Deployment – Four Parts:

Part 1 of 4: Upon completion of this course, you will be able to:
  1. Understand the use of the importance of the ISEE cycle.
  2. Participate in a Strategic development process.
  3. Develop and implement Breakthrough Objectives (BTO).
  4. Develop and implement Annual Improvement Priorities (AIP).
  5. Plan improvements over the next 12 months.
  6. Develop and implement Target Improvements (TI).
  7. Develop and implement Tasks.
Part 2 of 4: Upon completion of this course, you will be able to:
  1. Understand the Breakthrough Model.
  2. Understand the application an Enterprise PDCA.
  3. Understand the importance of establishing a feedback loop.
  4. Understand the purpose of an executive review.
  5. Understand common problems during SD implementation.
Part 3 of 4: Upon completion of this course, you will be able to:
  1. Understand the application of Strategy Deployment (SD).
  2. Understand the 3 levels of the SD Application.
  3. Determine key focus areas for improvement.
  4. Understand the tools of Strategy Deployment.
  5. Understand the Strategy Deployment planning and scheduling process.
Part 4 of 4: Upon completion of this course, you will be able to:
  1. Understand Quality, Cost and Delivery (QCD).
  2. Understand the five benefits of QCD.
  3. Understand the importance of QCD.
  4. Understand the seven key QCD metrics.
  5. Understand the five-step QCD process.
  6. Understand how to monitor process performance using QCD.
  7. Understand the QCD feedback process.

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Step 2: Value Stream Mapping – Three Parts:

Part 1 of 3: Upon completion of this course, you will be able to:
  1. Understand the 4 steps of Value Stream Mapping.
  2. Understand the purpose of Value Stream Mapping.
  3. Understand the Data Collection Process.
  4. Understand Step 1 of 4, identify Product Families.
  5. Understand Step 2 of 4, draw a Current State Map.
  6. Identify Opportunities for Improvements.
Part 2 of 3: Upon completion of this course, you will be able to:
  1. Understand the Value Stream Mapping data collection process.
  2. Understand how to draw a Current State Map.
Part 3 of 3: Upon completion of this course, you will be able to:
  1. Understand how to draw a Future State Map.
  2. Understand how to develop a VSM Implementation Plan.

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Step 3: Workplace Organization – Four Parts:

Part 1 of 4: Upon completion of this course, you will be able to:
  1. Understand the purpose of 5S.
  2. Understand each of the 5S activities.
  3. Understand the term “cross-functional team”.
  4. Understand each of the 5S tools.
Part 2 of 4: Upon completion of this course, you will be able to:
  1. Understand how to apply the 5S tools.
  2. Understand how to convert the 5S concepts into standard practices.
  3. Understand how to sustain all 5S improvements in the workplace.
Part 3 of 4: Upon completion of this course, you will be able to:
  1. Understand the definition of visual management.
  2. Understand the five levels of visual control.
Part 4 of 4: Upon completion of this course, you will be able to:
  1. Understand the visual management objectives.
  2. Understand the three I’s of visual management.
  3. Understand the visual management improvement cycle.
  4. Understand how to apply visual management techniques in the workplace.

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Step 4: Improve Product Flow – Two Parts:

Part 1 of 2: Upon completion of this course, you will be able to:
  1. Define process flow.
  2. Understand the reason for lead-time
  3. Apply Little’s Law to see how inventory affects lead-time.
  4. Identify where to begin to improve process flow.
  5. Understand how to draw a travel diagram.
  6. Understand the different types of workstation design.
  7. Understand how fixtures improve process flow.
  8. Understand how ergonomics affects workstation design.
Part 2 of 2: Upon completion of this course, you will be able to:
  1. Understand material replenishment.
  2. Understand the purpose of part presentation.
  3. Understand the different methods for delivering parts and materials to the work area.
  4. Understand the use of line side markets.
  5. Understand the principles of kitting for inventory and production control.

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Step 5: Reduce Changeover Times – Five Parts:

Part 1 of 5: Upon completion of this course, you will be able to:
  1. Understand the definition of changeover time.
  2. Understand the elements of a changeover.
  3. Understand the development of traditional changeovers.
  4. Understand the concept of an economic order quantity.
Part 2 of 5: Upon completion of this course, you will be able to:
  1. Understand the steps to improve changeover times.
  2. Understand how to document and record changeover activities.
  3. Understand how to separate changeover activities into internal and externalelements.
Part 3 of 5: Upon completion of this course, you will be able to:
  1. Understand how to convert internal elements into external elements.
  2. Understand the importance of developing instruction sheets.
Part 4 of 5: Upon completion of this course, you will be able to:
  1. Understand how to streamline all aspects of the changeover operation.
  2. Understand function standardization.
  3. Understand the purpose of using intermediary jigs.
  4. Understand the use of parallel operations.
Part 5 of 5: Upon completion of this course, you will be able to:
  1. Understand Step 4 – Streamline all aspects of the changeover operation…continued from Part 4 of 5.
  2. Understand the application of functional clamping.
  3. Understand the need to eliminate adjustments.
  4. Understand the use of kitting to reduce changeover times.
  5. Understand the purpose of developing changeover instructions.

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Step 6: Implement a Pull System – One Part:

Part 1 of 1: Upon completion of this course, you will be able to:
  1. Understand the resource, batch size & inventory dilemmas.
  2. Understand a batch and queue process.
  3. Understand a single piece flow process.
  4. Understand the concept of a pull system.
  5. Understand how to link processes using kanban.
  6. Understand the purpose for using kanban.
  7. Recognize 3 types of kanban.
  8. Understand material replenishment using a pull system.

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Step 7: Balance the Workload – Two Parts:

Part 1 of 2: Upon completion of this course, you will be able to:
  1. Understand the principles of a balanced workload.
  2. Identify the two key focus areas for balancing the workload.
  3. Understand the data collection process.
  4. Understand how to analyze the data to balance the workload.
  5. Understand how to calculate takt time and apply it.
  6. Understand the formula for balancing the workload between operations.
Part 2 of 2: Upon completion of this course, you will be able to:
  1. Understand the heijunka load leveling process.
  2. Understand how heijunka improves the flow of products.
  3. Understand how to to apply heijunka to single or mixed model production.
  4. Understand how to implement load-leveling techniques.

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Step 8: Develop Standardized Work – One Part:

Part 1 of 1: Upon completion of this course, you will be able to:
  1. Understand the process of standardization.
  2. Understand how culture affects standardization.
  3. Understand the importance of standardized work.
  4. Identify the types of standard work tools.
  5. Explain how standard work documents are used.

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Step 9: Continuous Process Improvement (CPI) – Three Parts:

Part 1 of 3: Upon completion of this course, you will be able to:
  1. Define Continuous Improvement.
  2. Understand Problem Solving.
  3. Understand the how problem solving has evolved.
  4. Identify the different types of problems.
  5. Understand Management’s role in problem solving.
  6. Define a process.
  7. Understand the 8 Step Problem Solving process.
  8. Understand the A3 template and how to use it.
  9. Understand the problem solving tools.
  10. Understand the purpose of an A3 storyboard.
Part 2 of 3: Upon completion of this course, you will be able to:
  1. Identify the key problem solving tools.
  2. Understand the application of brainstorming.
  3. Understand the application of affinity diagrams.
  4. Understand the application of an impact-effort matrix
  5. Understand the application of flow charts.
  6. Understand the application of a data sheet.
  7. Understand the application of check sheets.
  8. Understand the application of run charts.
  9. Understand the application of histograms.
  10. Understand the application of pareto charts.
  11. Understand the application of cause and effect diagrams.
  12. Understand the application of scatter diagrams.
Part 3 of 3: Upon completion of this course, you will be able to:
  1. Understand the concept of kaizen.
  2. Understand the RIE procedure.
  3. Understand the purpose of high and low level events.
  4. Understand how to choose RIE team members.
  5. Understand RIE procedure activities.
  6. Understand how to create a RIE agenda.

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Step 10: Extend your Lean efforts into the Supply Chain – One Part:

Part 1 of 1: Upon completion of this course, you will be able to:
  1. Understand the importance of extending your Lean efforts into the Supply Chain.
  2. Define a Supply Chain.
  3. Understand how to develop a competitive advantage.
  4. Understand the difference between a “make to order” and “make to stock” process.
  5. Understand the purpose of a “tradeoff curve”.
  6. Understand the bullwhip effect.
  7. Understand the causes of the bullwhip effect.
  8. Understand Vendor Managed Inventory(VMI).
These online training modules cover the advanced application and integration of Lean principles into any manufacturing business model. The learner will be required to take an exam and achieve an 80% pass score to receive a Lean Expert in Manufacturing Non-Credit Certificate of Achievement.

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  • Release Date: 14 October, 2017

  • Price: $997.00

  • Category: