Certified Lean Facilitator

Specializing in Office, Service, and Knowledge Environments

Overview
Certification Requirements
Project Structure and Criteria
Additional Development
Curriculum
Program Fees
Expectations for Program Graduates

Overview

Becoming skilled as a Lean Facilitator is a lifelong journey. But the journey typically begins with an intensive educational program to develop the skills for analyzing processes, applying specific Lean tools, understanding the human component in championing improvements, and building a foundation for ongoing professional development.

Karen Martin & Associates offers a Certified Lean Facilitator program -- specifically geared to the unqiue nature of office, service and knowledge work -- that covers:

Strategic analytical, improvement design, and implementation planning tools such as value stream mapping, implementation plans and A3s.
Tactical analytical, improvement design, and prioritization tools such as metrics-based process mapping, physical and electronic spaghetti diagrams, root cause analysis and the PACE chart for improvement prioritization.
Implementation strategies such as PDCA-based Kaizen Events, DMAIC-structured projects and “just-do-its.”
Flow creating strategies such as load leveling, work balancing via takt time, work standardization, mistake proofing, 5S, visual workplace, setup reduction, pull system and work cells.
Lean psychology and facilitator development to become skilled in stimulating innovation, resolving conflict, countering resistance to change, and leveraging human nature. to achieve optimal results.
The key metrics in measuring results and monitoring both value stream and process-level performance.
The necessary infrastructure and organizational requirements for successful continuous improvement programs.

This 60-hour, project-based program is designed as a learn-do educational experience, structured into four-hour modules that can be combined into full day sessions or offered separately, as needed. A project, selected prior to the first module and finalized by the seventh module, provides a real world learning lab for applying the knowledge and skills being acquired in the classroom. Class size is limited to 20 participants.

Certification Requirements

To become a Certified Lean Facilitator in office, service and technology settings, participants must meet the following requirements:

Read The Toyota Way (prior to the first session) and seven (7) journal articles distributed throughout the program.
Attend at least 52 out of the 60 classroom hours (no make-up sessions are given).
Complete homework activities as assigned.
Complete a team-based project that meets the following criteria:

Tied to a value stream
Involves at least one (1) internal or external upstream supplier and one (1) downstream internal or external customer
Is driven by a real business need
Is predicated on measurable objectives
Uses at least one (1) root cause analysis technique
Uses at least three (3) flow enhancement tools
Generates a lead time reduction and quality improvement (rolled first pass yield) of at least 20%
Generates a significant financial return
Note: projects typically require 20-40 hrs of team time outside the classroom. Karen makes herself available for up to 4 hrs of coaching per project team.

Pass a written examination with a score of 70% or higher.
Present their project results to the organization’s leadership team.

Certified Lean Facilitators receive a personalized engraved certification plaque and gain significant respect within the organization and among their peer group in other organizations.

Upon completion of this program, you will be able to:

Lead improvement teams in creating value stream maps and future state implementation plans.
Plan and execute Kaizen Events to generate rapid and sustainable results.
Select and apply the Lean tools most appropriate for particular improvement needs.
Conduct effective root cause analyses to steer improvement teams away from band-aid solutions.
Use key metrics to eliminate waste, design effective processes, and monitor ongoing performance.
Translate improvements into financial terms.
Transform leadership into effective continuous improvement champions.
Leverage human nature to shift organizational culture and set the stage for operational excellence.

Project Structure and Criteria

Each class is segmented into project teams of 4-5 participants who select and complete projects according to the following criteria:

Project Plans – A draft project plan must be completed by Module 3; the final project plan must be completed by Module 7.

Project Selection Criteria – Each project must:

Be tied to a value stream.
Involve at least one upstream supplier and one downstream customer (either internal or external).
Include relevant pre-improvement measurements and projected post-improvement results (including both operational and financial elements).

Lead time (throughput time) must be reduced by at least 20%.
Rolled first pass yield (output quality) must be improved by at least 20%.

Use at least one (1) root cause analysis technique.
Use at least three (3) flow enhancement tools.

Coaching – Project teams must meet with the program instructor following Modules 1, 5, 9, & 13 to evaluate progress, address any obstacles, assure that relevant measurement is taking place, discuss the application of particular Lean tools, and receive presentation coaching.

Project Presentation – Each team must complete a project report and present their results to the class and invited leadership.

Graduation and distribution of personalized engraved certification plaques immediately follow the project presentations.

Additional Development via Observation

A necessary step in building facilitator confidence and deepening his/her understanding of Lean principles, team dynamics, and the application of specific tools, we highly recommend providing the facilitators with the opportunity to observe a value stream mapping activity and Kaizen Event facilitated by a skilled Lean practitioner. While co-facilitation is helpful, observing as a first step allows the facilitator-in -training to focus solely on learning, rather than doing.

For this stage of development, the facilitators-in-training may observe events led by either seasoned internal facilitators or by Karen Martin & Associates. This developmental opportunity also provides the organization with rapid and measurable results, which creates the momentum for change, sets the stage for future improvement efforts, and provides a return on investment.

Curriculum

The detailed curriculum – including content, activities, reading assignments, program schedule, and project timeline – is available upon request.

Program Fees

For client organizations, the program fee is based on: 1) actual expenses, including materials ($200 per participant) and travel expenses; and 2) instructor time. Public offerings range from $2,200 to $3,300 per participant, depending on the specific program structure. Pricing for observational opportunities is additional and is based on the particular model selected.

Expectations for Program Graduates

By the completion of the program, Certified Lean Facilitators are prepared to successfully lead improvement teams in office, service, and technology-based improvement activities ranging from value stream mapping and strategic improvement planning to tactical implementation. Following the observational opportunity, new facilitators should be paired, preferably with seasoned facilitators until they build the confidence to facilitate on their own. Ongoing learning is an expectation for the continued development of Certified Lean Facilitators.