Table of Contents
Featured Case Studies
A Leading Foundry reduced 72% of WIP by MUDA Elimination
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Master Training Program For Career Enhancement with certifications
Lean 4.0 Certification -KIAP
Lean is a philosophy, a way of life which espouses “Doing More and More with Less and Less”. The lean paradigm focuses on making the most effective use of available resources (man, machine, material, information) and this is measured through improvement in the parameters of Productivity, Quality, Cost, Delivery, Safety and Morale. The philosophy is industry size and sector neutral and is applicable across manufacturing, service, retail, infra and IT sectors.
About This Program
The founding fathers, Toyota, believe in the kaizen way of implementing Lean and our program follows this same path with emphasis on “Learning by Doing”. The participants are expected to apply their classroom learning of concepts, tools and techniques during the program itself by diagnosing current problem areas in an actual organizational process and focusing on drawing up improvement plan for at least one significant process. The course is therefore split into three spaced out modules with a week’s gap between each of them to facilitate practical application of the learning by doing projects based on actual client situations.
KIAPs vastly experienced lean experts will guide and vet the projects. The participants will be presenting their project work on the final day of the program. There will also be an online test after the three modules are completed to assess the participant’s grasp of Lean concepts.
Program Faculty
Ganesh Mahadevan, a Metallurgical Engineer (IIT-Mumbai) and MBA in Operations (NITT), is a Director at KIAP. With KIAP since 2007 he has supported over 60 organizations across multiple sectors in achieving Operational Excellence through Kaizen and Lean.. He is an empanelled Lean Consultant under the NMCP program and has lead multiple cluster implementations. He started his career in production and quality functions at Hindalco & Pyrotek before a four year stint in the Consulting practice of Deloitte.
Satish Pendharkar is a Mechanical Engineer from Indian Institute of Technology, Mumbai and a Six Sigma Black Belt Certified by the Indian Statistical Institute, Bangalore. He has industrial experience of 35 years in various functions like Manufacturing, Maintenance, Marketing and Human Resources in large companies like Glaxo Smithkline and Thermax. and has been associated with KIAP from its inception in 2006.
Vimal Katiyar has 30 years of Industry experience having worked in world class organizations such as Pepsi Co and more recently as Director (Manufacturing) at Perfetti. An M.Tech In Chemical Engineering from IIT, Kanpur, he had earlier completed his Bachelors from Jadavpur Univeristy. He is also a CII certified TPM Club expert and has recently forayed into the Leadership Coaching space.
Other experts from KIAP may also take sessions on specific tools
Topic | Date | Time |
Module 1 – Lean Foundation, Assessment & Diagnosis | ||
Introduction – Lean Paradigm | 03-Jul-21 | 10.00 am – 11.15 am |
Understanding Waste – Muda, Muri and Mura and how to observe and identify wastes in a process | 11.15 am – 12.45 pm (Lunch) | |
Diagnostic tools Value Stream Map, Material Flow Diagram | 2.15 pm – 5.00 pm (Break 15 min) | |
Lean Assessment – key lean metrics to diagnose operations in different industries | 04-Jul-21 | 10.00 am – 11.15 am |
Drawing up a lean roadmap | 11.30 am – 12.45 pm | |
Discussion on Assignments | 2.15 pm – 3.30 pm | |
Module 2 – Lean Tools to Achieve Operational Excellence | ||
Flow – process and layout design | 10-Jul-21 | 10.00 am – 11.30 am |
Cycle time reduction through workstation design | 11.45 am – 1.00 pm | |
Breaking batch size through SMED | 2.30 pm – 4.00 pm | |
Heijunka – Load Levelling | 11-Jul-21 | 10.00 am – 11.15 am |
Pull Systems – Kanban | 11.30 am – 12.45 pm | |
Discussion on Assignments | 2.15 pm – 3.30 pm | |
Module 3 – Building Blocks of Sustenance | ||
5S & Visual Management | 17-Jul-21 | 10.00 am – 1.00 pm (Break 15 min) |
Equipment reliability – AM, PM & KK Pillars of TPM | 2.30 pm – 5.00 pm (Break 15 min) | |
Quality Tools – Basic tools Introduction to Six Sigma | 18-Jul-21 | 10.00 am – 1.00 pm (Break 15 min) |
Test | 3.00 – 4.00 pm | |
Project Presentation & Evaluation by Panel | 24-Jul-21 | 10.00 am – 1.00 pm (Break 15 min) |
Certification
Those participants who successfully complete the course by scoring atleast 65% in the test and the project assessment will be certified as Lean Managers by KIAP.
Program Fees
The founding fathers, Toyota, believe in the kaizen way of implementing Lean and our program follows this same path with emphasis on “Learning by Doing”. The participants are expected to apply their classroom learning of concepts, tools and techniques during the program itself by diagnosing current problem areas in an actual organizational process and focusing on drawing up improvement plan for at least one significant process. The course is therefore split into three spaced out modules with a week’s gap between each of them to facilitate practical application of the learning by doing projects based on actual client situations.
KIAPs vastly experienced lean experts will guide and vet the projects. The participants will be presenting their project work on the final day of the program. There will also be an online test after the three modules are completed to assess the participant’s grasp of Lean concepts.
