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Certificates: Certificate "Process optimization with Lean, Kaizen and CIP"
Certificate "Statistics and data analysis" -
Examination: Praxisbezogene Projektarbeiten mit Abschlusspräsentationen
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Teaching Times: Full-timeMonday to Friday from 8:30 a.m. to 3:35 p.m. (in weeks with public holidays from 8:30 a.m. to 5:10 p.m.)
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Language of Instruction: German
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Duration: 8 Weeks
Process optimization with Lean, Kaizen and CIP
What is CIP/Kaizen/Lean? (approx. 0.5 days)
Definition, goals, benefits (CIP vs. Kaizen vs. Lean)
Principle of small steps
Historical development of the CIP (approx. 1 day)
Supply/demand orientation
Japanese corporate culture
Toyota Production System
Development of modern quality and management systems (e.g. TQM)
Overview of maturity level and assessment models (EFQM)
Framework conditions for successful CIP (approx. 0.5 days)
Role of management
Communication and transparency
Employee participation
Corporate culture and motivation
Interface and team management
Quality management principles (e.g. ISO 9001)
Philosophy of CIP/Kaizen (approx. 1 day)
The five central principles
Internal customer/supplier principle
Interaction of innovation, standard and kaizen
Tasks of management and employees
Customer requirements and satisfaction (approx. 1.5 days)
Market and stakeholder analysis
Kano model
Requirements and wishes
CTQ methods (Translation Matrix, CTQ Tree)
Vuca and agility
Integrated management systems
Process optimization: Efficiency for the benefit of customers - Lean management: Value and waste (approx. 1 day)
Philosophy: Focus on customer requirements
Productivity - Quality - Availability - Flexibility
Value creation and non-value creation
The 7 types of waste (TIMWOOD)
3 MU: Muda, Mura, Muri
Implementation of Kaizen and CIP (approx. 1 day)
Prerequisites for Kaizen in the company
Development of a continuous improvement culture
5S method/5A campaign
Kaizen as a management system
Kaizen roadmap
Synchronize processes (approx. 0.5 days)
Production in the customer cycle
Cycle time, cycle time, throughput time
Cell logic
One-piece flow
Pull principle (supermarket) and push principle
Just-in-time logistics [JIT]
Value stream analysis (approx. 0.5 days)
Value stream mapping (actual and target value stream)
Value added quotient [WQ]
Visualization: benefits, symbols, data box
Level production/Heijunka (approx. 0.5 days)
Heijunka vs. series
Heijunka box
Batch size 1
Application example
Increasing the number of cycles
Kanban flow system (material and information flow)
Improve production facilities (approx. 0.5 days)
Total Productive Maintenance (TPM) incl. autonomous maintenance
Key process indicators (KPIs, OEE)
Minimization of set-up times (SMED)
Standardize processes (approx. 1 day)
Quality policy standardization
Advantages of standards
Standards in the company
Questions about the standard
Defining processes, from the process landscape to the process description
Visualization
3 process states
Worker self-check
Controlling processes (approx. 2.5 days)
ISO 9001 requirements (4.4, 8.1, 8.5.1): Customer key figures (Cpk/Sigma level)
Process management
Process analysis
Standard tools: Q7 and M7
Process efficiency analysis
AI-supported data analysis, statistical process control [SPC]
SPC in series production: interpreting quality control charts [QRK], automation (Jidoka)
Evaluation models (approx. 1 day)
PDCA: Improvement of improvement
Self-assessment maturity level ISO 9004 and EFQM
Management assessment according to ISO 9001
6-W questioning technique
4-M/7-M checklists
Benchmarking and best practice
Balanced Scorecard (BSC)
Hoshin Kanri, X-Matrix
AI-supported evaluation of trends, key figures and assessments
Measurement of customer and employee satisfaction
Error prevention and systematic problem solving (approx. 2 days)
Development according to customer requirements
Risk management: risk landscape, matrix [FMEA]
Poka Yoke, error classification, error culture/Hansei
Internal audits
Customer communication: complaint management, 8D report
10 steps to problem solving with tools (Q7, M7)
Root cause analysis: 5 Why, 6 W (Root Causes)
A3 problem solution sheet
AI-based pattern recognition for error and quality data
Empowering employees (approx. 1 day)
Ownership and entrepreneurship
Roles of managers and employees
Change management
Promoting employees (TWI)
Employee satisfaction
Competence and awareness, knowledge management (ISO 9001)
Idea management (BVW)
Teamwork in a lean context
Quality Circle [QC]
Agile methods
Community of Practice (CoP)
Coaching Kata and Improvement Kata
Visual Management and Shopfloor (approx. 0.5 days)
Principles of visual control
Visual process control, Andon (traffic light)
Store floor management
Digital dashboards and AI-supported process visualization
Quality controlling - finances (approx. 0.5 days)
Quality cost model, conformity/defect costs, rule of 10 (as a mental model)
Project work (approx. 3 days)
To consolidate the content learned
Presentation of the project results
Statistics and data analysis
Statistical basics (approx. 6 days)
Measurement theory basics (population, sample, sample types, measurement, scale levels)
Univariate descriptive statistics (frequency distributions, central measures, measures of dispersion, standardization, histograms, bar charts, pie charts, line charts, box plots)
Bivariate descriptive statistics (measures of correlation, correlation coefficients, crosstabs, scatter plots, grouped bar charts)
Basics of inductive inferential statistics (probability distributions, normal distribution, sampling distribution of the mean, significance test, null hypothesis test, significance level, effect size, parameter estimation, confidence intervals, error bar charts, power analysis, sample size)
Data preparation and data cleansing with suitable software
Descriptive analysis
Visualization of statistical results
AI-supported analysis and interpretation of statistical results
Methods for comparing two groups (approx. 5 days)
z-test, t-test for one sample
t-test for independent and related samples
Pretest-posttest designs with two groups
Supporting significance tests (Anderson-Darling test, Ryan-Joiner test, Levene test, Bonett test, significance test for correlations)
Nonparametric methods (Wilcoxon test, sign test, Mann-Whitney test)
Contingency analyses (binomial test, Fisher's exact test, chi-square test, cross-tabulations, measures of association)
Interpretation of test results
AI-supported interpretation of results
Basics of regression analysis (approx. 2 days)
Linear regression
Model interpretation
AI-supported model interpretation
Correlation analysis
Methods for comparing the means of several groups (approx. 3 days)
One-factorial and two-factorial analysis of variance (ANOVA)
Post-hoc analyses
Interpretation of group differences
Multi-factorial analysis of variance (general linear model)
Fixed, random, crossed and nested factors
Multiple comparison methods (Tukey-HSD, Dunnett, Games-Howell)
Interaction analysis
Power analysis for variance analyses
Introduction to Design of Experiments (DoE) (approx. 1 day)
Full factorial and partial factorial experimental designs
Project work (approx. 3 days)
To consolidate the content learned
Presentation of the project results
Changes are possible, the course content is updated regularly.
After the course, you will be able to systematically analyze processes, identify potential for improvement and optimize them efficiently and purposefully using lean, kaizen and CIP methods.
You will also understand the basics of statistics, be able to process and evaluate data and present, explain and interpret statistical data analyses and results using graphics.
The course is aimed at specialists and managers from the areas of quality and process management as well as those responsible for change processes.
Users and specialists from social and market research, business administration (marketing, business intelligence), technical areas, production, quality assurance and research in the healthcare sector.
Process optimization specialists are in high demand across all industries and are among the most important specialists in modern companies.
A sound knowledge of statistics is a valuable additional qualification that is in great demand in industrial research and development, in drug development, in the supervision of medical studies, in finance and insurance, in information technology or in public administration.Your meaningful certificate provides a detailed insight into the qualifications you have acquired and improves your career prospects.
Didactic concept
Your lecturers are highly qualified both professionally and didactically and will teach you from the first to the last day (no self-study system).
You will learn in effective small groups. The courses usually consist of 6 to 25 participants. The general lessons are supplemented by numerous practical exercises in all course modules. The practice phase is an important part of the course, as it is during this time that you process what you have just learned and gain confidence and routine in its application. The final section of the course involves a project, a case study or a final exam.
Virtual classroom alfaview®
Lessons take place using modern alfaview® video technology - either from the comfort of your own home or at our premises at Bildungszentrum. The entire course can see each other face-to-face via alfaview®, communicate with each other in lip-sync voice quality and work on joint projects. Of course, you can also see and talk to your connected trainers live at any time and you will be taught by your lecturers in real time for the entire duration of the course. The lessons are not e-learning, but real live face-to-face lessons via video technology.
The courses at alfatraining are funded by Agentur für Arbeit and are certified in accordance with the AZAV approval regulation. When submitting a Bildungsgutscheinor Aktivierungs- und Vermittlungsgutschein, the entire course costs are usually covered by your funding body.
Funding is also possible via Europäischen Sozialfonds (ESF), Deutsche Rentenversicherung (DRV) or regional funding programs. As a regular soldier, you have the option of attending further training courses via Berufsförderungsdienst (BFD). Companies can also have their employees qualified via funding from Agentur für Arbeit (Qualifizierungschancengesetz).