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Lean Essentials Boot Camp Basics for Manufacturing






April 24, 2017  |  8:00 a.m. – 4:30 p.m.  |  Sheraton Cleveland Airport, Cleveland, Ohio  


Samantha Kaplan, Corporate College (a division of Cuyahoga Community College), director, quality and continuous improvement 

Tom Fazekas, senior training consultant, Corporate College (a division of Cuyahoga Community College), senior training consultant


Click attendee in the table below to register online.


On or Before

April 7, 2017


April 7, 2017

Attendee $495.00 $620.00


If you have questions about registration, please contact Customer Service at 866-721-3322 (option 6) or 1-240-646-7054.


ACerS Targeted Learning Workshops are sponsored by ACerS Manufacturing Division


Course Description 

Workshop participants will learn the foundations and ideology behind Lean methods and how they integrate with organizations to achieve process improvement. Upon completion of this course, participants will have a firm understanding of what Lean is and how it can benefit organizations. Through instruction, discussion, group activities and hands-on exercises, participants will learn Lean practices.


We will conduct the training to demystify Lean, introducing the infrastructure for Lean and explain the essential tools for identifying and attacking sources of waste and inefficiency.


Workshop goals:

  • Gain a basic understanding of process improvement and Lean
  • How to apply the concepts in the workplace such as 5S and 8 Wastes
  • Ability to identify processes within an organization in which Lean methods would be effective
  • Introduction to tools used in the Lean process


Lean Boot Camp Topics Covered:

  • Introduction to lean principles
  • Kaizen event
  • Eight wastes
  • Current value stream mapping
  • 5S
  • Visual management
  • Standard work
  • Error proofing
  • Changeover reduction

Topic Descriptions

Introduction to Lean Principles
A Lean operation produces just what is needed, when it is needed with no additional labor, costs, inventory, or time. Learn the skills necessary to apply Lean techniques to reduce waste and improve process efficiency. Gain a practical understanding of Lean continuous improvement techniques and how to use them to reduce errors, inventory, and production lead-time.

  • Define Lean, its importance, benefits, and objectives
  • Describe Lean tools, methodologies, and levels of deployment
  • Identify the roles and responsibilities of the Lean implementation team
  • Discuss how these roles can be integrated into an organization

Eight Wastes
Producing anything that the customer doesn’t want or need is waste. It lowers your profits and leaves you less competitive in your market. Learn about the waste that is hidden, or taken for granted, in both manufacturing and office environments. Utilizing Lean techniques can help to dramatically reduce wastes and their associated costs.

  • Identify the Eight Wastes and discuss why they are a primary focus during Lean implementation
  • Describe each of the Eight Wastes in detail and give examples


Kaizen Event
Kaizen Events are highly effective team events that focus on achieving rapid results. Kaizen teams use various analytical and Lean techniques, such as Value Stream Mapping, Changeover Reduction, 5S, Total Productive Maintenance, and Workplace Design to implement rapid improvements.

  • Define Kaizen Event and discuss its purpose and application
  • Explain how Kaizen Events can provide rapid business benefits and accelerate the execution of larger initiatives


Current State Value Stream Mapping
Value Stream Mapping is an essential planning tool used to identify improvements that will result in a Lean Value Stream. The first step is to create the Current State map, showing the Value Stream of a particular product or service.

  • Define Value Stream and Product Family
  • Describe a Current State Value Stream Map and discuss its purpose
  • Identify commonly used symbols; and describe how metrics are collected and represented


5S is a technique that results in a workplace that is clean, uncluttered, safe, and well organized. The 5S pillars provide a methodology for organizing, cleaning, developing, and sustaining a productive work environment. A 5S environment has “a place for everything and everything in its place,” with all tools and materials ready where and when they are needed. Learn how 5S can help reduce waste and optimize productivity in any work environment.

  • Discuss 5S and describe its overall purpose and benefits, and identify the five phases of its process.

Visual Management
Visual Management is the establishment of a workplace where performance conditions can be understood by sight. Problem areas are highlighted so employees can take immediate action to eliminate waste. One of the most important benefits of a visual workplace is that even someone unfamiliar with the process can see what is happening, identify errors, and tell if anything is out of place or missing.

  • Define Visual Management and describe its purpose and benefits
  • Introduce the three characteristics of Visual Management – Self Explaining, Self-Regulating
  • Self-improving – and discuss why they are important
  • Describe the difference between Visual Controls and Visual Displays, giving examples of each

Standard Work
Standard Work is an essential building block of a Lean Enterprise. It helps ensure that each step in the process is clearly defined so that work can be performed repeatedly in the same manner. Variations in processes result in mistakes or other quality problems that require inspection and rework.

  • Definition of Standard Work from a Lean perspective
  • Discuss its business benefits; explain why it is the basis for improvement
Error Proofing
Error Proofing is used to ensure products and processes are completed correctly the first time. The goal of error proofing is to prevent the occurrence of defects and to ensure that mistakes are detected when they occur. Because people can make mistakes even in inspection, error proofing often relies on mechanisms built into tools or systems that automatically signal when problems occur or prevent the process from continuing until the proper conditions are met.
  • Define Error Proofing from a Lean perspective. & describe its business benefits
  • Discuss how it can improve quality and reduce failures and omissions
  • Understand and be able to apply the 6-Step error proofing process
Changeover Reduction
Changeover Reduction is a structured methodology and technique used to reduce the combined amount of Set-up and Start-up time it takes to change a process from running one product to running the next one. It is one of the fundamental techniques in Lean manufacturing and a key to waste reduction. 
  • Define Changeover Reduction
  • Discuss its benefits, and explain how it supports and enables Lean waste reduction
  • Define Takt time and other related terms
Upon successful completion of this workshop, participants will receive a Lean Certificate and .8 CEU’s awarded by Corporate College, a division of Cuyahoga Community College. 
Registrants will receive: Participant workbooks, templates/forms, and the Lean Reference guidebook: Lean Six Sigma Pocket Tool book by M. George, D. Rowlands, M. Price, and J. Maxey.
Need Help Convincing Your Boss?

The approval process can sometimes take a while, so here’s a quick document to help you make your case. 

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Instructor biographies

Samantha Kaplan has 20+ years of quality and environmental health and safety experience. She has been involved with in implementing various continuous improvement initiatives with companies ranging from small manufacturing to Fortune 500 companies. 


Kaplan is a quality professional that consults to improve performance, facilitate learning, and develop effective and efficient leaders. She is experienced in the development, facilitation, and delivery of customized trainning and auditing for companies in the areas of ISO 14001, 9001, ISO 13485, 21CFR820, Lean Six Sigma and environmental health and safety. She is also an experienced ISO auditor and trainer, as well as a Lean Six Sigma Black Belt. Kaplan is a member of the American Society for Quality (ASQ).



Tom Fazekas is dedicated to helping organizations improve their performance through development of their people. His approach emphasizes the clear definition of the processes by which the organization satisfies the needs of the customers and of the business. His insighful questions and deep listening help the organization discover opportunities to measure and improve those processes. His approach emphasizes collaboration and creativity to develop the outstanding leadership and highly responsive teams needed for continuous improvement and sustainable results. 


As a trainer, Fazekas emphasizes the practical application of continual improvement tools and techniques (ISO, Problem solving, Lean, Six Sigma). Training participants develop work/life skills for critical assessment, for recognizing root causes of problems, and for streamlining processes to enhanced customer satisfaction. 



Cancellation Policy

ACerS reserves the right to cancel a course up to 4 weeks before the scheduled presentation date. Please contact ACerS customer service at 1-866-721-3322 or 1-240-646-7054 to confirm that the course is happening before purchasing your airline tickets. ACerS is not responsible for the purchase of non-refundable airline tickets or the cancellation/change fees associated with canceling a flight.


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