Lean Certification Body of Knowledge
(Version 2.0, March 2006)
Copyright 2005 Society of Manufacturing Engineers
LEAN CERTIFICATION BODY OF KNOWLEDGE RUBRIC VERSION 1.0
WEIGHTINGS PER EXAM
Lean Bronze (tactical) Lean Silver (integrative) Lean Gold (strategic)
MODULE 1 1. ENABLERS FOR LEAN 1.1. Leadership [Link] vision, mission, values, strategies and goals, including resource allocation. [Link]. Business Vision [Link]. Business Mission [Link]. Business Purpose [Link]. Business Values, Philosophy, Ethics [Link]. Strategic Business Assessment (external evaluation) [Link]. Strategy Development [Link]. Business Goals and Objectives [Link]. Core Competencies [Link]. Critical Success Factors [Link]. Resource Allocation [Link] for Humanity and Social Responsibility [Link]. Schools and Communities [Link]. Unions [Link]. Other Stakeholders [Link] and Short-term Planning [Link]. Hoshin Planning and Policy Deployment [Link]. Execution and Metrics [Link]. Project Management [Link] of Lean leadership [Link]. Go and See (Genchi Genbutsu) [Link]. Defining Value Versus Non-value [Link]. Identifying Waste [Link]. Achieving Flow [Link]. Recognizing Normal Versus Abnormal [Link]. Respect for Humanity [Link] corporate culture [Link]. Value Stream Mapping [Link]. Kaizen Blitz Events [Link]. Continuous Improvement and Change [Link]. Communication of Business Values, Philosophy, Ethics [Link]. Change and knowledge management systems [Link]. Resource Standards and Measures for Business Results 1.2. Empowerment and Human Development [Link] of empowerment [Link]. Communication [Link]. Delegation [Link]. Recognition [Link]. Rewards [Link]. Employee Satisfaction and Morale
15% 5%
25% 10%
35% 15%
10%
15%
20%
WEIGHTINGS PER EXAM
Lean Bronze (tactical) Lean Silver (integrative) Lean Gold (strategic)
[Link]. Employee and Labor Relations [Link] Training and Development [Link]. Instructional Goals [Link]. Skills Assessment [Link]. Continuous Learning Strategy [Link]. Cross-Training [Link]. Classroom and On-the-Job Training [Link]. Coaching and Mentoring [Link] [Link]. Cross-Functional Team Selection and Leadership [Link]. Multi-Level Participation [Link]. Roles and Responsibilities [Link]. Decision-Making (types of decision making, e.g. consensus) [Link]. Team Dynamics (storming, norming, forming, team relations, etc.) [Link]/Feedback/Appraisal System [Link]. Information Sharing (Yokoten) [Link] turnover, absenteeism and compensation [Link], clean and safe work environment and results [Link]. Environment [Link]. Ergonomics [Link]. Safety MODULE 2 2. LEAN CORE OPERATIONS 2.1. Operational Vision and Strategy [Link] Vision and Strategy [Link]. Operational Processes Vision, Mission, Strategy, and Goals [Link]. Lean Principles in Strategy [Link]. Empowerment in Strategy [Link]. Operational Alignment with Organizational Vision, Mission, Strategy, and Goals 2.2. Innovations in Product Design and Market Service [Link] Design and Development (product/service) [Link]. Quality Function Deployment (QFD) [Link]. Concurrent or Simultaneous Engineering [Link]. Variety Reduction [Link]. Engineering Changes [Link]. Design for Manufacture and Assembly [Link]. Design for Product Life Cycle (DFx) (cradle to cradle) [Link]. Failure Mode and Effects Analysis [Link]. Life Cycle Engineering [Link]. Production Process Preparation (3P) [Link]. Knowledge Transfer Methods & Practices [Link] Market Service [Link]. Customer Feedback and Market Needs Analysis [Link]. Customer Specs and Requirements [Link]. New market development and current market exploitation
45% 2%
35% 5%
15% 7%
8%
12%
5%
WEIGHTINGS PER EXAM
Lean Bronze (tactical) Lean Silver (integrative) Lean Gold (strategic)
[Link]. E-commerce systems [Link]. Benchmarking 2.3. Suppliers and Customers (relationship development) [Link] [Link]. Supplier Development Processes [Link]. Supplier Certification [Link]. Supplier Benchmarking [Link]. Supplier Satisfaction Measures [Link]. Corrective Action System [Link] [Link]. Customer Training and Development Processes [Link]. Customer Selection and Focus [Link]. Demand Load Leveling [Link]. Corrective Action System [Link] and Transport Alliances [Link]. Warehousing [Link]. Distribution Centers [Link]. Cross-Docks [Link]. Reverse Logistics (returns, dunnage, etc.) [Link]. Remanufacturing / Maintenance, Repair and Overhaul (MRO) [Link]. Just-in-Time Alliances [Link]. Supplier Managed Inventory Systems 2.4. Core Operations & Processes [Link] identification and elimination of waste [Link]. Waste Identification and Elimination (7+ wastes) [Link]. Value Stream Mapping [Link]. Value Analysis [Link]. 5S Standards and Discipline [Link]. Visual Workplace [Link]. Kaizen Blitz Events [Link]. Mistake / Error Proofing (Poka-Yoke) [Link]. Quality at the Source / Source Inspection [Link]. Continuous Improvement (Kaizen) [Link]. 5Whys Problem Solving [Link]-in-Time Operations [Link]. Takt Time [Link]. Material Signals (Kanban) [Link]. Pull System [Link]. Continuous Flow [Link]. Just-in-Time (JIT) [Link]. Quick Changeover/Setup reduction (SMED) [Link]. Total Productive/Preventative/Predictive Maintenance (TPM) [Link]. Load-Leveling (Heijunka) 2.4.3. Cellular and Continuous Flow [Link]. Cellular Manufacturing [Link]. One Piece Flow [Link]. Standard Work (operator instructions, etc.) [Link]. Multi-Process Handling (multiple machines operating simultaneously) [Link]. Autonomation (Jidoka) [Link]. Production Schedule [Link]. Bills of Material
3%
10%
3%
32%
8%
0%
WEIGHTINGS PER EXAM
Lean Bronze (tactical) Lean Silver (integrative) Lean Gold (strategic)
[Link]. Routings [Link]. Flow Analysis Charts (spaghetti diagrams, manmachine, etc.) [Link] Tools for Continuous Improvement [Link]. Plan-Do-Check-Act (PDCA) (DMAIC) [Link]. Reliability and maintainability [Link]. Root Cause and corrective action [Link]. Flowcharting [Link]. Pareto [Link]. Cause and effect diagrams (Fishbone) [Link]. Check Sheets [Link]. Histograms [Link]. Scatter and Concentration Diagrams [Link]. Control Charts (includes SPC) [Link]. Problem Solving Storyboards
MODULE 3 3. BUSINESS CORE OPERATIONS - SUPPORT FUNCTIONS 3.1. Administrative Vision and Strategy in Finance and Accounting, Human Resources, Materials Management, Information Technology, Sales and Marketing, Quality Assurance, Process & Manufacturing Engineering and Legal & Regulatory [Link] BOK in this section is analogous to Module 2, it applies to business and service processes [Link]. Application of lean principles and techniques [Link]. Focus on value adds and waste identification and elimination [Link]. Commitment to Continuous Improvement [Link]. Business operations improvement metrics [Link] and Systematic Business and Service Process Design [Link]. Finance and Accounting: measurement and control systems, etc. [Link]. Human Resources: alignment of selection, development, teamwork, performance feedback and discipline, compensation and rewards, regulations, etc. [Link]. Materials Management: inventory control, planning and scheduling, procurement, logistics, material handling, etc. [Link]. Information Technology: appropriate alignment with process changes, accessibility, flexibility to change, etc. [Link]. Sales and Marketing: alignment of sales and operations planning and execution, product rationalization, customer interaction, etc. [Link]. Quality Assurance: regulation and certification, inspection rationale, feedback, quality improvement system, etc. [Link]. Process & Manufacturing Engineering: system for engineering changes, feedback for new product development, concurrent process, etc. [Link]. Legal and Regulatory: alignment with core lean
20%
15%
10%
20%
15%
10%
WEIGHTINGS PER EXAM
Lean Bronze (tactical) Lean Silver (integrative) Lean Gold (strategic)
thinking, etc. MODULE 4 4. QUALITY, COST & DELIVERY MEASURES 4.1. Quality & Quality Improvement [Link] Results [Link]. Rework [Link]. Customer PPM Rejects [Link]. First Pass Yield [Link]. Scrap (Internal PPM Rejects) [Link]. Process Variation [Link]. Cost of Quality [Link]. Warranty Costs 4.2. Cost and Productivity Improvement [Link] and Productivity Results [Link]. Inventory Turns [Link]. Record Accuracy (inventory, bill of material, operator instructions, etc.) [Link]. Cycle Time, Takt Time and Throughput Time [Link]. Operational Equipment Effectiveness (OEE) [Link]. Labor Value-Add [Link]. Product Cost Reduction [Link]. Changeover [Link]. Resource Utilization [Link]. Energy Efficiency [Link]. Performance to Load Leveling (linearity in production) 4.3. Delivery and Customer Service Improvement [Link] and Customer Service Measurement [Link]. Line-Items Delivered On-Time to Customer Requirements [Link]. Complete Orders Delivered On-Time to Customer Requirements [Link]. Customer Lead Time [Link]. Premium Freight [Link]. Mistakes in Shipments [Link]. Warranty Response, Service, etc. MODULE 5 5. BUSINESS RESULTS 5.1. Customer Satisfaction [Link] Satisfaction Results [Link]. Market Share [Link]. Reorder Rate [Link]. Customer Survey Results [Link]. Customer Audit Results [Link]. Other Customer Feedback [Link]. Value / Improvement Analysis [Link]. Customer Retention [Link]. Customer Awards 5.2. Business Results [Link] Measurement [Link]. Operating Income on Sales and Assets [Link]. Operating Income on Space [Link]. Fixed and Variable Costs
15% 5%
10% 3%
10% 0%
5%
4%
4%
5%
3%
6%
5% 3%
15% 8%
30% 15%
2%
7%
15%
WEIGHTINGS PER EXAM
Lean Bronze (tactical) Lean Silver (integrative) Lean Gold (strategic)
[Link]. Cash Flow [Link]. Value Stream Profitability
