Lean Systems Certification Courses

Course Descriptions | schedule | fees | to register online

The UK Lean Certification Program starts the development of your own internal support facilitators for the lean transformation process. Begun in the early 90’s, this “Train the Trainer” program has become known worldwide and has helped hundreds of companies nationally and internationally.

Unlike other training programs, the UK certification program is not a “Lean Champion” or “Lean Expert” program. Instead UK is guided by Toyota’s belief that there is no such thing as a “kaizen specialist” or a “lean expert.”  Those titles indicate a basic misunderstanding, i.e. participants are trained to have all the answers or can lead the effort all by themselves.

Lean doesn’t work this way: everyone works at it all the time and because it embodies the principle of continuous improvement, no one understands it 100%, just as no one understands the future in all its possibilities.  The UK certification gives participants the confidence and ability to raise the important questions, see the real problems, understand and avoid potential failure modes and most importantly help leadership understand its key role in the transformation process.

The Certification program is “hands-on” and application based. The days are organized into lecture / discussion in the mornings and laboratory in the afternoon, which allows participants to better absorb what they are learning: principles studied as the day begins can be applied the same afternoon.

The UK Certification Program is not instant knowledge, delivered in a hurry, fading away just as quickly.  Instead, material is presented in 3 week-long sessions delivered over 3 months. The spacing in between sessions means less time away, more time to absorb the material and explore it on home ground, and more opportunities to bring up questions and problems in a later session as you try to apply what’s been learned so far.

The program gives assignments each week that participants are expected to complete during the off weeks. Each week builds on previous content and it is preferred that participants enroll in the series in sequential order.

Course Descriptions

Week 1: Developing the Kaizen Mind for Leadership

The first week identifies the main components of lean/TPS and explains how and why these components came about. Participants will begin to understand cultural aspects of lean critical to sustaining improvement and also learn some of Toyota’s techniques for substantial cost reductions. This first week is important because it provides the big picture of the transformation process and makes clear leadership’s all-important role in that process.

Objectives:

• Compare traditional versus lean thinking / culture
• Describe the transformational image
• List the organizational roles required for lean that sustains development
• List “true lean” principles and behaviors
• List the failure modes of lean
• Practice Toyota’s techniques for process and flow study
• Practice Toyota’s 8-Step Problem Solving methodology

Week 2: Installing the Toyota ODG (Operations Development Group)

The second week strengthens core lean skill sets introduced in Week 1. After reviewing the in-plant assignments from week 1, the week discusses the functioning of Toyota’s Operations Development Group, a way to bring leadership thinking forward and to develop management capability for TPS. The week ends by providing more detail on the transformation model so that participants can begin drafting their lean implementation plan writing their plan on paper.

Objectives:

• Complete panel review of Week 1’s homework assignment
• Evaluate the transformational image
• Apply Toyota’s management improvement process named Jishuken
• Describe Toyota’s learning process
• Strengthen Process and Flow study
• Strengthen Problem Solving skill

Week 3: Maintaining Lean Through Standardization

The third week of certification builds on weeks 1 and 2 and presents methods that sustain lean improvement. Toyota’s techniques for achieving standardization will be reviewed including the significance of the role structure that keeps problems from returning. The human aspects of transformational leadership and the annual planning process called Hoshin Kanri are also presented.

Objectives:

• Complete panel review of Week 2’s homework assignment
• Apply the standardization principle
• Apply Toyota’s annual strategic planning process called Hoshin Kanri
• Describe transformational leadership
• Apply Toyota’s Production Planning process called heijunka
• Strengthen Problem Solving skill
• Strengthen role understanding
  

Note: All courses are held at the UK Center for Manufacturing in Lexington, KY

Fees
The registration fee covers the course and luncheons - lodging and other meals not included.

To take the series and qualify for the certificate,
the rate is $7,500.00Volume pricing is available

Please Note

• Every effort is made to ensure that the instructors listed present the programs. However in rare circumstances such as illness, a speaker with comparable qualifications may be substituted.
• Unavoidable circumstances sometimes require a change in course location or dates. Should such a change affect a course for which you are registered, you will be contacted in a timely manner and every effort will be made to reschedule with as little inconvenience as possible.

to register online

For General Information and
Public Course Registration Contact:
Sandra Dunn
Email:sdunn@engr.uky.edu
Phone: 859-257-6262, ext. 214
Toll Free: 800-227-6268
Cell: 859-338-3742

For Customized Solutions or
Dedicated Training Contact:
HeatherMichele Adkins
Email:hadkins@mfg.uky.edu
Phone: 859-257-6262, ext. 458
Toll Free: 800-227-6268
Cell:859-684-0311