Lean Enterprise

Having a Lean Enterprise isn’t about trying to scrape by with less. It’s about being able to produce more with your existing resources by getting rid of the pieces of the process that don’t add any value to your customers. Lean is often called a journey because it is a constantly evolving process – you never stop looking for ways to improve.

Manufacturers are facing increased worldwide competition and the stakes are high. The winners in this competition work to eliminate overproduction caused by traditional scheduling systems and only make what customers want, when they want it and how they want it.

Lean establishes a systematic approach to eliminating these wastes and creating flow throughout the whole company. It also helps you develop and implement a long-term plan to streamline your operations for success.

CITEC uses a train-plus-implementation methodology to help your company realize the lean success it seeks. Through this learning process, your employees will understand the opportunities, pursue them, measure the results and look for more ways of improving the operation.

Lean Training & Implementation Programs:

Lean Assessment
Lean Essentials Training
Lean Product Development
Lean Certifications: White Belt, Green Belt, Black Belt
Lean Sigma Program

Lean Assessment

The best place to start is for an outside set of eyes to review your operation and work with you to chart the most appropriate course to implement Lean in your organization. Our Lean Team will walk your processes with you – from the front office to the production floor – to look for areas of opportunity. You will receive a report outlining our recommendations on what you can do – short term and long term – to reduce waste and pursue a Lean enterprise.

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Lean Essentials Training

CITEC provides training on- or off-site and over multiple shifts on each of the essential tools of Lean. Current public sessions are listed on our Training page. Or, you can have the training done at your facility, at your convenience.

Some of the Lean Essentials training programs offered by CITEC includes:

Eight Wastes identifies the many types of waste in an organization.

Lean Principles explains the various terms used in a Lean Enterprise. [click for workshop agenda]

Value Stream Mapping provides a roadmap for your lean implementation plan. [click for workshop agenda]

Lean Project Implementation shows you how the training will be applied in your organization. [click for workshop agenda]

5S Workplace Organization, one of the first steps you should implement in your operations, instructs you how to clean up and get things in order for Lean. [click for workshop agenda]

Visual Controls enables self-management of a cell or a Value Stream. [click for workshop agenda]

Hoshin Planning enables everyone to be on the same page with regard to a Value Stream strategy. [click for workshop agenda]

Kaizen Improvement is a method for identifying changes and implementing them. [click for workshop agenda]

Quick Changeover (SMED) can reduce lead-time from weeks to days and lower work-in-process inventory and warehousing costs. [click for workshop agenda]

Making Value Flow [click for workshop agenda]

Standardized Work allows you to share information about the best ways to do things so they will be done that way consistently [click for workshop agenda]

One-Piece Flow Cell Teams establishes the process of "make one, use one." [click for workshop agenda]

Kanban & Supermarket Pull Scheduling Systems [click for workshop agenda]

Lean Materials Handling & Milk Runs [click for workshop agenda]

Total Productive Maintenance reduces equipment downtime and increases reliability. [click for workshop agenda]

Zero-Defect Quality (Mistake Proof & Fail Safe) [click for workshop agenda]

Lean Leadership (Change Management & Leading Transitions)

Lean Improvement Facilitator Training (LIFT)

Lean Office Wastes: waste isn’t just found on a manufacturer’s shop floor. CITEC offers Lean Assessments, Training and implementation projects that specifically address the wastes found outside of the shopfloor. Tremendous opportunities exist in every organization – from hospitals to government – through Lean Office.

Principals of Lean: an overview of the different methodologies used to transform an organization into a lean operation.

Training Within Industry (TWI): will help you leverage your lean manufacturing investment by giving your supervisors the skills they need to increase productivity, improve morale and reduce training time.

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Lean Product Development

Ideally combined with the Eureka! Winning Ways process of filling your growth pipeline with new product ideas, CITEC offers Lean Product Development tools and techniques – inspired by Toyota’s Lean Product Development Methodology. [click here for details]

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Lean Certifications: White Belt, Green Belt, Black Belt

Lean White Belt (LWB) Certification Program - You have the power to learn how to implement Lean improvement and create positive change for your organization.

This unique, in-depth 11 module program is designed in a proven, successful format of learn-implement-teach to develop your understanding of Lean productivity improvements, your use of the techniques at your facility and your ability to guide others at your company to realize real impacts.

The outstanding success of previous LWB series is reflected by the number of repeat companies who participate in the training and in the comments of participants:

"I'm very satisfied with the CITEC Lean White Belt Series experience. The content is highly relevant and invaluable to those in the manufacturing arena. The format and tempo of the course was digestible. The materials provided are priceless. The instructor is valid and generous, pulling from his vast anecdotal accounts of Lean implementation. In a short time, we have seen results of using the Lean tools. This matters."

Derrick M. (program manager for a
North Country composite manufacturer)

Taking over where single-day or weeklong training leaves off, completion of this learn-implement-teach Lean White Belt program means you will be able to:

• Understand and mentor others in the application of key Lean concepts;
• Champion Lean initiatives at your organization;
• Lead teams to complete plant-wide Lean implementation;
• Create plans to realize your organization’s full Lean improvement potential.

This intense Lean White Belt program includes 22 topics covered in 11 full day, highly interactive sessions held once each month with in-plant implementation and training required between classes (similar to Six Sigma Green Belt programs.) Attendees learn about the improvement tools of Lean during classes that feature discussion, simulation and interaction. In the weeks between sessions, participants must complete an in-plant application of the tools learned and share their experiences with fellow students at the next session. CITEC staff is also available to provide coaching and in-plant support to better insure the success of White Belt students.

Jim Myers, Lean Sensei and CITEC’s Lean Manufacturing Analyst, is our program facilitator with support and mentoring provided by CITEC’s Lean Team of experts.

For more information and a schedule of upcoming LWB series, please check our Training page or email your interest to CITEC’s Marketing Director Tricia Wilson.

Lean Green Belt (LGB) Certification Program - The Lean Green Belt Certification Program offers an unrivaled combination of in-depth classroom training, mentoring and implementation projects to bring your Lean expertise to the next level. You will learn by doing... and from each other in this highly interactive training program.

“I value my Lean Green Belt training over (my) Shingo credential, the Lean Sensei I received from World Wide Flow College/JcIT Institute of Technology and the Six Sigma Black Belt I earned at Motorola University (Sponsored by Raytheon). You thoroughly addressed every TPS method plus key implementation issues. You can quote me.”

Patrick Gerrard Sr.
PES Leader, ATK Space Magna

Course Description
CITEC is proud to offer the Lean Green Belt Certification Program to qualified candidates and companies in Northern New York. Unlike informational public training programs, the Lean Green Belt Certification Program focuses on providing the participants with the additional tools, methodologies and guidance to specifically assist them in Lean implementation efforts at their company. This is a highly interactive program during which the participants must actively work in support of one (or multiple) Value Stream(s) at their company.

Expectations are that the Lean Green Belt candidate will:

1. Fully participate in and successfully complete the entire 40-hour Lean Green Belt training program
2. After that, conduct a minimum 2-hour Lean training class with his/her people
3. After this, lead a Major Kaizen Project in their own Value Stream (or facility)
4. Volunteer to be available to work on Lean projects virtually anywhere across his/her company

The Lean Green Belt Certification Program is 5 days of intense learning conducted at a rate of one session per month for a maximum of 12 people. In addition to the classroom sessions, participants are expected to complete assignments and report on those at the next session. Through project presentations and interaction, the participants will learn by doing ... and from each other.

Drawing on the basic training participants will have acquired during the prerequisite Lean White Belt series, candidates will review and focus on implementing 20 Lean Topics in their own Value Stream / facility.

Who Should Attend
The Lean Green Belt Certification Program is specifically designed to expand the expertise and implementation activities of those who have achieved Lean White Belt status. As a result, only those individuals who have recently completed their Lean White Belt certification are eligible to participate.

The instructor may consider comparable pre-requisite certifications if they include a thorough understanding of the 20 content topics, the participant has copies of the training materials for those topics and can verify implementation/training projects completed for those topics. (See the Lean Green Belt Training Course Description for a list of those topics.)

Topic / Assignment Schedule
Session 1: Introduction to Lean (Lean Principles), Current State Value Stream Mapping, Future State Value Stream Mapping, Lean Implementation
     - Presented by instructor
Session 2: Hoshin Planning, Kaizen Events, Lean Metrics, 5S Workplace Organization
     - Presented by Green Belt candidates
Session 3: Visual Controls, One-Piece Flow Cells, Cell Teams, Standardized Work
     - Presented by Green Belt candidates
Session 4: Zero-Defect Quality, Kanbans & Supermarkets, Lean Materials Handling, SMED/Quick Changeover
     - Presented by Green Belt candidates
Session 5: Total Productive Maintenance (TPM), Change Management, Transition Management, Lean Transformation
     - Presented by Green Belt candidates

Certification
Each participant will need to define a Green Belt-level Kaizen for submission to Lean Sensei Jim Myers. Once approved, the participant must complete that Kaizen and submit a detailed explanation of the event, before and after photographs and the results/metrics. A panel consisting of Lean Sensei Jim Myers, CITEC Deputy Director Tricia Wilson and your LGB Mentor (John Pinkerton, Terry Wiley or Eric Myers) will review the completed project information to determine and award Lean Green Belt certification. Please Note: It may take several weeks or months before participants successfully complete their Green Belt-level Kaizens and receive their certification.

Results
Those participants who are awarded Lean Green Belt status will have proven their knowledge of critical Lean concepts and their capabilities in implementing Lean efforts at their companies. Lean Sensei Jim Myers and CITEC will certify each successful candidate as having accomplished Green Belt-level capabilities.

Lean Green Belts can successfully:

• Implement all 20 Lean Topics in his/her own organization, primarily focused on a Value Stream.
• Serve as a resource to his/her company.
• Spend up to 50% of his/her time implementing lean.
• Lead lean activities at his/her company site.

We recognize this program is actually a transfer of our own Lean capabilities to the company and, therefore, we guarantee the quality of certification will be maintained at a very high level.

For more information and a schedule of upcoming LGB series, please check our Training page or email your interest to CITEC’s Marketing Director Tricia Wilson.

Lean Black Belt (LBB) Certification Program - A Lean Black Belt (LBB) is a person who has achieved “black belt” level competency in 10 performance dimensions as defined below. He/she is a full time resource for their organization and works 100%+ on lean transformation. This person must be able to show evidence they’ve been working in this capacity for a minimum of 5 years, and continue in this role today.

CITEC in partnership with our Lean Sensei Jim Myers are proud to certify people as Lean Black Belts! They are truly precious resources in any company.

Performance Dimensions*

1. Lean Methods: applies a robust portfolio of lean tools, processes, principles, methodology… knows and has used all of them.
2. Change Agent: can make change happen.
3. Transformation: actively works to transform his/her organization from “traditional” to “lean.”
4. Project Leadership: leads 4 – 12 lean projects per year.
5. Teamwork: always works with teams to implement lean.
6. Management Advisor: helps managers “lead” lean implementation.
7. Knowledge Transfer: builds lean capability in others.
8. Quantitative Results: returns 10X his/her salary in value to the company every year.
9. Technical Communications: writes, publishes, and circulates technical papers on lean.
10. Self-Improvement: continuously improves him/herself by attending lean seminars, reading books, benchmarking others, participating in webcasts, membership in professional organizations (SME, AME, ASQ, others).

*Each of these dimensions is assessed on a scale of 0-10 using the LBB Self-Assessment Table. A score of 700+ is required for Lean Black Belt Certification. This assessment and resulting score must be agreed to by CITEC, Lean Sensei Jim Myers and the sponsoring manager in the candidate’s own company.

Black Belt Candidates will be able to demonstrate proven proficiency in:

Value Stream Mapping (Current State and Future State)
Hoshin Planning
5S Workplace Organization
Visual Controls
One-Piece Flow Cells
Cell Teams
SMED (Single Minute Exchange of Die)
TPM (Total Productive Maintenance)
Kanbans, Supermarkets, FIFO Lanes (pull systems)
ZDQ (Mistake Proof and Fail Safe)
Lean Materials Handling (Water Spiders and Milk Runs)
Lean Warehouse (A, B, C item location, storage, and management)
Kaizen
Lean Metrics (+Lean Accounting)
Lean Office (Engineering, Purchasing, etc)
Lean Supply Chain (+ Supplier Management)
Lean Product Development

And, have general knowledge & skills in:

Problem Solving (Analytical Problem Solving, Analytical Trouble Shooting, A3 Reports)
Project Management
Seven Basic Quality Tools (Histograms, C/E Diagrams, Scatter Plots, SPC Charts, Pareto Diagrams, etc)
VOC (Voice of the Customer)
Process FMEA (Failure Mode Effects Analysis)
Graphical techniques
Communications Skills
Conflict Management Skills
Presentation Skills

Recommended Professional Certifications & Memberships:

SME (Society of Manufacturing Engineers)
AME (Association for Manufacturing Excellence)
ASQ (American Society for Quality)
Certified Lean White Belt (by CITEC / JCM Work Designs)
Certified Lean Green Belt (by CITEC / JCM Work Designs)
Certified Lean Bronze/Silver/Gold (by ASQ/SME)
Certified Six Sigma Yellow Belt (by your company)
Certified Six Sigma Green Belt (by your company)
Certified Six Sigma Black Belt (by your company)

Certification
The candidate for the Lean Black Belt is required to submit comprehensive documentation when applying for certification. This documentation must include:

1. Prior lean certifications (Green Belt, White Belt, Bronze/Silver/Gold ASQ certifications, other company certifications in lean, etc.)
2. Length of experience working on lean
3. Quality of that experience working on lean
4. Quantitative results of lean project work over the past 5 years
5. LBB Change Agent Assessment (of him/herself)
6. The Lean Transformation Assessment (of his/her value stream, plant site, or company)
7. Business reason for requesting Lean Black Belt Certification

All of the above must be submitted for review to Lean Sensei Jim Myers when the candidate is ready. The documentation will be reviewed, appropriate clarification questions will be asked, and any additional follow up will be requested of the candidate. Upon completion of the above, the entire application will be reviewed during a meeting with the sponsoring manager of the candidate. If approved, the Lean Black Belt will be awarded. This award comes with a formal framed certificate plus a Lean Martial Arts Black Belt.

This certification, once achieved, remains “for life” with the Lean Black Belt. Jim Myers will provide a personal reference and a written recommendation for any Lean Black Belt at any time requested… and be proud to do so!

If you are ready to pursue your Lean Black Belt Certification, please contact Lean Sensei Jim Myers.

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Lean Sigma Program

There are 5 inter-related topics for Lean Sigma Training:

Lean Sigma Champions
Lean Sigma White Belt
Lean Sigma Green Belt
Lean Sigma Black Belt
Lean Sigma Project Team

Any business enterprise ultimately needs all of these capabilities in order to “survive and prosper” today and in the future. Our Lean Sigma Team is ready, willing, and able to help you and your company on this important journey!

Where should you start?
We recommend beginning with the Lean Sigma Champions. These are the people with the direct responsibility for performance of a business process (more on this below). They need to be the leaders who have a vision of the future and provide the resources to achieve it.

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Lean Sigma Champions are process owners. These are people who own the responsibility for a business process and its results in an organization. Examples of these processes include (but are not limited to):

• Customer Service
• Customer Order Entry
• Capital Project Engineering Design
• Technology Research
• Product Design
• Process Design Engineering
• Supplier Management
• Manufacturing
• Product Distribution
• Warehousing
• Transportation
• Product Sales
• Product Marketing
• Advertising
• Purchasing
• Finance
• Planning
• Scheduling
• Maintenance
• Information

The responsibility of a Lean Sigma Champion is to continuously improve the business process he/she “owns”.

Lean Sigma Sensei Jim Myers offers specific training and coaching to these Lean Sigma Champions through 1-day or 2-day workshops with these topics:

• Leadership (core competencies and assessment/feedback process)
• Sponsorship (core competencies and assessment/feedback process)
• Measurement
• Team Building
• DMAIC Process
• Project Management
• Feedback and Coaching

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Lean Sigma White Belts – Once you have identified your Lean Sigma Champions and, together, mapped the vision for the organization’s Lean Sigma efforts, we believe you need to start training and certifying your Lean Sigma White Belts. This is a basic level of Lean Sigma capability needed to start improving business processes.

The Lean Sigma White Belt (LsWB) is achieved through one week of intensive Lean Sigma Training. Successful participants will be certified as Lean Sigma White Belts upon completion of this training that includes:

• The DMAIC Process
• Team Charter
• Target Matrix
• The 7 Basic Quality Tools
• Use of MiniTab (or other statistical software)
• Classroom simulation

Lean Sigma White Belts are at the “learning level” of Lean and Six Sigma and generally receive coaching from Lean Sigma Green Belts and Black Belts. They work as members of project teams and retain their regular full-time jobs in the organization.

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Lean Sigma Green Belts (LsGB) are then developed from this group of certified Lean Sigma White Belts. The difference between White Belt and Green Belt is the level of commitment. The Green Belt is expected to devote up to half of his/her work time on Lean Sigma projects.

The Lean Sigma Green Belt involves two weeks of additional training beyond the Lean Sigma White Belt, plus completing a major Lean Sigma Kaizen and a Lean Sigma Training Event. Green Belts are expected to be devoting up to half of their time to Lean Sigma Projects, plus maintaining their current organizational position. He/she is typically working on 4-6 Lean Sigma projects every year and delivering results at 4x his/her salary.

Lean Sigma Green Belt topics include:

• The DMAIC Process
• 7 Basic Quality Tools +
• Design of Experiments (basic)
• ANOVA
• Experience with MiniTab or other statistical software
• FMEA (Failure Modes Effects Analysis)
• CS & FS Value Stream Mapping
• ZDQ (Mistake Proof and Fail Safe)

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Lean Sigma Black Belt (LsBB) is the advanced level of certification – when a person works full time on Lean Sigma and helping his/her business with transformational change, while working on Lean Sigma projects.

A Lean Sigma Black Belt is someone who’s skilled at Lean and Six Sigma Methodologies and has experience applying these skills in business processes to achieve dramatic results. He/she is a full-time Lean Sigma practitioner in the organization, working on 4-6 major Lean Sigma projects every year and delivering results at 10x his/her salary.

For individuals who have progressed beyond the Lean Sigma Green Belt level and are interested in pursuing advanced certification, we offer 2 weeks of training for potential Lean Sigma Black Belts. Certification for a Lean Sigma Black Belt must also include a major Six Sigma Project, reviewed and verified by our Lean Sigma Team.

Lean Sigma Black Belt Topics include:

• The DMAIC Process
• The 7 Basic Quality Tools +
• Design of Experiments (advanced)
• ANOVA
• Use of MiniTab or other statistical software
• Project Management
• Kano Analysis
• CTQ Tree
• VOC (Voice of Customer)
• QFD (Quality Function Deployment)

Of course, the final level of achievement for these “belts” would be the Lean Sigma Master Black Belt (LsMBB). This is a level of certification we believe should be achieved only by those people who’ve worked full time to teach Lean Sigma and transform their business for a period of at least 5 full years. This is the Sensei level reached by only a handful of people in even the largest companies.

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Lean Sigma Project Team is the group of people at your organization who are actually working on Lean Sigma projects. The group is comprised of a cross-section of people from various jobs in the organization put together as a team for the purpose of improving a business process. This process improvement is typically performed as a Kaizen Event, led by a Lean Sigma Green Belt or Black Belt.

The majority of these projects should be done as 5-day Kaizen Events. Here we depart from the “standard” Six Sigma staff project approach that can take up to 4 months to complete of defining DMAIC
(Define->Measure->Analyze->Improve->Control). Instead, we firmly believe the DMAIC process could be and should be completed within a 5-day Kaizen Event timeframe, with a project team.

For detailed information on these Lean Sigma programs, contact Jim Myers.

Or, to get started on your Lean pathway to success, contact any member of our Lean Team today: Eric Myers, Jim Myers or John Pinkerton.

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