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Certificates: Certificate "Process optimization with Lean, Kaizen and CIP"
Statistics" certificate -
Examination: Practical project work with final presentations
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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
Continuous process optimization with Kaizen
What is CIP/Kaizen? (approx. 0.5 days)
Historical development of the CIP (approx. 1.5 days)
General conditions for CIP
Saturated and unsaturated markets
Supply/demand orientation
Japanese corporate culture
Toyota Production System
Development of quality management systems, ISO 9001
TQM quality awards, EFQM model (2020)
Six Sigma
Philosophy of CIP/Kaizen (approx. 1 day)
The five central principles
Continuous improvement in ISO 9001 (7 principles, PDCA process model) and continuous improvement
Interaction of innovation, standard and kaizen
Internal customer/supplier principle
Process wear and tear
Informal evasive action
Change management
Tasks of management and employees
Worker self-assessment
CIP impulses
Customer requirements and satisfaction (approx. 1 day)
Society and market movements
Integrated management systems
Vuca and agility
Requirements and wishes
Kano model
Stakeholder analysis
CTQ Translation Matrix
CTQ Tree
Artificial intelligence (AI) in the work process
Presentation of specific AI technologies
and possible applications in the professional environment
Project work (approx. 1 day)
To consolidate the content learned
Presentation of the project results
Lean in quality management
Process optimization: Efficiency for the benefit of customers - lean management (approx. 0.5 days)
Philosophy: Focus on customer requirements
Productivity - Quality - Availability - Flexibility
Implementation and Kaizen (approx. 0.5 days)
Environment for Kaizen
Corporate culture of improvement and optimization
Visual Management
5S method/5A campaign
Eliminate waste (approx. 1 day)
Value creation/Muda
MIT study
Elimination of the three MU's, the 3-MU checklist
7 types of waste (TIMWOOD)
8V rule
Mura and Muri
Synchronize processes (approx. 0.5 days)
Production in the customer cycle
Cycle time, cycle time, throughput time
Cell logic, omega cell, chaku-chaku principle
One-piece flow
Pull principle (supermarket) and push principle
Just-in-time logistics [JIT]
Customer-oriented, highly efficient value streams (approx. 0.5 days)
Structure of a value stream
Value creation quotient [WQ]
Visualization: benefits, symbols, data box
Production leveling/Heijunka (approx. 0.5 days)
Heijunka versus series
Heijunka box
Batch size 1
Application example
Increasing the number of cycles
Kanban flow system (material and information flow)
Kanban project
Improving production facilities (approx. 0.5 days)
TPM, autonomous maintenance
Key figure OEE
Minimization of set-up times
SMED/EKUV
Project work (approx. 1 day)
To consolidate the content learned
Presentation of the project results
Continuous improvement process (CIP)
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
Process planning
3 process states
Controlling processes (approx. 2 days)
ISO 9001 requirements (4.4, 8.1, 8.5.1): capable and controlled processes
Customer key figures (Cpk/Sigma level)
Selection of methods: Stacey matrix, Cynefin
Process management
Process analysis
Standard tools
Q7 and M7
Six Sigma tools
Process efficiency analysis
Data analysis, Statistical Process Control [SPC]
Statistical basics
SPC in series production: interpreting the quality control chart [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 checklist
Benchmarking and best practice
BSC
Hoshin Kanri, X-Matrix
Measuring customer and employee satisfaction
Project work (approx. 1 day)
To consolidate the content learned
Presentation of the project results
Continuously improve processes (approx. 0.5 days)
Customer satisfaction
Avoid mistakes
Error culture and Hansei
Avoiding mistakes (approx. 0.5 days)
Development according to customer requirements: QFD and design thinking
Risk management
Risk landscape
Risk matrix
Failure mode and effects analysis [FMEA]
Poka Yoke
Internal audits
Dealing with defects (approx. 1 day)
Error classification (DIN 55350)
Customer communication: complaint management, 8D report
Corrective actions, the search for root causes: 10 steps to problem solving with tools (Q7, M7)
Problem-solving funnel with 6 W and 5 times Why (Root Causes)
Fault tree, cause map
A3 problem-solving sheet
Empowering employees (approx. 1 day)
Why and how?
Ownership and entrepreneurship
Task of the manager
Employee satisfaction
ISO 9001: Competence and awareness, knowledge management
Idea management (BVW)
Lean: Teamwork
Quality Circle [QC]
Order fulfillment and problem solving in a team: project management and Scrum
Community of Practice [PoC]
Visual Management (approx. 0.5 days)
Purposes, advantages, methods
Visual process control, Andon (traffic light)
Store floor management
Quality controlling - finances (approx. 0.5 days)
The 10 rule of failure costs
Costs for conformity and error costs
Liability cost trap
Project work (approx. 1 day)
To consolidate the content learned
Presentation of the project results
Statistics
Statistical basics (approx. 6 days)
Measurement theory basics (population and sample, sample types, measurement and scale levels)
Univariate descriptive statistics (frequency distributions, central measures, measures of dispersion, standard value, histograms, bar charts, pie charts, line charts and box plots)
Bivariate descriptive statistics (measures of correlation, correlation coefficients, crosstabs, scatter plots and grouped bar charts)
Basics of inductive inferential statistics (probability distribution, normal distribution, mean value distribution, significance test, Fisher's null hypothesis test, effect size, parameter estimation, confidence intervals, error bar charts, power analyses and determining the optimum sample size)
Artificial intelligence (AI) in the work process
Presentation of specific AI technologies
and possible applications in the professional environment
Methods for comparing two groups (approx. 5 days)
z- and t-test for a sample (deviation from a specified value)
t-test for the mean difference between two independent/connected samples
Testing the effectiveness of actions, measures, interventions and other changes with t-tests (pretest-posttest designs with two groups)
Supporting significance tests (Anderson-Darling test, Ryan-Joiner test, Levene test, Bonnet 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 with measures of association)
Methods for comparing the means of several groups (approx. 5 days)
One- and two-factorial analysis of variance (simple and balanced ANOVA)
Multi-factorial analysis of variance (general linear model)
Fixed, random, crossed and nested factors
Multiple comparison methods (Tukey-HSD, Dunnett, Hsu-MCB, Games-Howell)
Interaction analysis (analysis of interaction effects)
Selectivity and power analysis for variance analyses
Introduction to Design of Experiments (DoE) (approx. 1 day)
Full 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 identify potential for improvement and carry out step-by-step optimization in an efficient and targeted manner. Furthermore, you will have the right understanding of a functioning lean philosophy in the company.
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).