Module 1: Foundations of Lean Manufacturing

• What is Lean Manufacturing and Why It Matters
• The Business Case for Lean: Cost, Quality, and Speed
• Origins of Lean: The Toyota Production System
• Core Lean Principles: Value, Value Stream, Flow, Pull, Perfection
• Types of Waste in Manufacturing (Muda, Mura, Muri)

Module 2: Value Stream Mapping

• Understanding Value from the Customer's Perspective
• Current State vs. Future State Mapping
• Primary and Secondary Value Stream Mapping Icons
• Identifying Value-Added vs. Non-Value-Added Activities
• Using VSM to Prioritize Improvement Opportunities

Module 3: Production Leveling and Flow Metrics

• Principles of Heijunka (Production Leveling)
• Takt Time, Cycle Time, and Lead Time Calculations
• Balancing Production Schedules for Smooth Flow
• Reducing Variability in Demand and Supply

Module 4: 5S and Workplace Organization

• The Five Pillars: Sort, Set in Order, Shine, Standardize, Sustain
• Implementing 5S on the Shop Floor
• 5S as a Foundation for Waste Elimination
• Sustaining 5S Through Audits and Visual Controls

Module 5: Standard Work

• Principles of Standard Work
• Creating Standard Work Instructions and Documentation
• Standard Work Combination Sheets
• Standard Work as a Baseline for Improvement

Module 6: Kaizen and Continuous Improvement

• Principles of Kaizen and Continuous Improvement Culture
• Structuring a Kaizen Event (Kaizen Blitz)
• PDCA Cycle (Plan-Do-Check-Act) in Kaizen
• 5 Whys and A3 Problem-Solving Approach
• Employee Involvement and Idea Management Systems
• Measuring the Impact of Kaizen Initiatives

Module 7: Single-Minute Exchange of Die (SMED)

• Understanding Setup and Changeover Time
• Internal vs. External Setup Activities
• SMED Implementation Steps
• Strategic Applications of SMED for Flexibility
• SMED's Role in Waste Elimination

Module 8: Pull Systems and Kanban

• Push vs. Pull Production Systems
• Kanban Card System Fundamentals
• Designing and Implementing a Kanban System
• Kanban Sizing and Replenishment Rules
• Digital Kanban and Electronic Signal Systems

Module 9: One-Piece Flow and Cell Design

• Principles of One-Piece Flow Production
• Designing Manufacturing Cells for Flow
• Eliminating Batch-and-Queue Processing
• Implementation Challenges and Solutions

Module 10: Visual Management

• Principles of Visual Workplace Management
• Visual Controls, Andon Systems, and Signal Boards
• Using Visual Management to Eliminate Waste
• Sustaining Visual Management Practices

Module 11: Total Productive Maintenance (TPM)

• Principles and Pillars of TPM
• Overall Equipment Effectiveness (OEE): Measurement and Calculation
• Autonomous and Planned Maintenance
• Reducing Equipment Downtime and Breakdowns
• Implementing TPM on the Shop Floor

Module 12: Mistake-Proofing and Built-In Quality

• Principles of Jidoka (Built-In Quality)
• Poka-Yoke (Mistake-Proofing) Techniques and Devices
• Line-Stop Authority and Escalation Protocols
• Integrating Quality Checks into the Production Line

Module 13: Lean Supply Chain and Supplier Integration

• Extending Lean Principles Beyond the Shop Floor
• Lean Supplier Relationships and Just-in-Time Delivery
• Reducing Inventory Through Supply Chain Collaboration
• Lean Logistics and Distribution Practices

Module 14: Lean Manufacturing in the Digital Era

• Industry 4.0 and Smart Manufacturing Overview
• IoT-Enabled Equipment Monitoring and Real-Time Dashboards
• Predictive Maintenance as an Extension of TPM
• Digital Tools for Value Stream Mapping and Kanban

Module 15: Leading a Lean Transformation

• Building a Lean Culture and Leadership Buy-In
• Preparing a Lean Implementation Roadmap
• Overcoming Common Barriers to Lean Adoption
• Sustaining Long-Term Lean Gains
• Case Studies in Successful Lean Manufacturing Transformations

Apply for Certification

https://www.vskills.in/certification/certified-lean-manufacturing-professional