LEAN FACTORY

LAYOUT AND FLOW

MANAGEMENT

PRODUCTION

INFORMATION AND ADMINISTRATION

LEAN FACTORY LAYOUT AND FLOW

This program delivers lean knowledge in a
practical format, extending the understanding of
lean theory while employing a company team
project approach to facilitate lean learning at the
process stream level. Teams develop applied
process stream maps through team work in
exercises and homework assignments.
Heres what some of our Lean Performance
Certificate students have had to say:
"Informative process which unveils the obvious
and the not so obvious in a systematic fashion
Allows immediate application in the factory
Real eye-opener. Before class sessions, I
couldnt see the forest for the trees
Real world examples provided to resolve
manufacturing issues real application vs.
theory

PROGRAM OBJECTIVES
The Certificate In Lean Factory Layout and Flow is
designed to facilitate teams consisting of managers,
supervisors, and process owners and operators:

Complete process stream maps and identify factory

layout and flow lean improvements.

Expand the implementation of Lean Factory Layout

and Flow Practices to improve current factory
process quality, cost, and delivery.

Expand the Team-Based continuous improvement

approach to implementing Lean Process Oriented
Management.

ABOUT THE INSTRUCTOR

Brian J. Carroll is a Principal of Performance
Improvement Consulting, Inc. (PIC), a
management consulting firm specializing in Lean
Performance project services located in Chicago,
Illinois. He has over twenty years of consulting
experience, including over 25 successful
MRP/ERP implementations, many in Lean
environments. Manufacturing and service
companies across the globe are transforming their
enterprises utilizing his groundbreaking book,

Lean Performance
ERP Project
Management:
Implementing the
Virtual Lean
Enterprise

LEAN PERFORMANCE
CERTIFICATE SERIES
In addition to the Certificate in Lean Factory Layout
and Flow, the Lean Performance Certificate Series
includes Certificates in:

Planning and Managing The Lean Transformation

Lean Operations Principles, Tools, and Practices

Lean Office Layout and Flow

Lean Performance ERP Project Management

PARTICIPANT MIX

Materials Managers, Operations Managers,

Project Managers, Lean Manufacturing
Managers, Continuous Improvement
Coordinators, Lean / Kaizen Coordinators,
Supervisors, and Process Owners and
Operators.

Lean Commerce
PROGRAM
PREREQUISITE

PROGRAM PREREQUISITE

Attendees must have received a Certificate In

Lean Operations Principles, Tools, and
Practices

LEAN FACTORY LAYOUT AND

FLOW PROGRAM SESSIONS
Session One - The Process Stream
The first session in the Certificate examines the Value
Stream Mapping methodology for implementing Lean
Process Oriented Management and compares and
contrasts this newer approach with the formerly
predominant operations improvement methodology of
Process Value-Added Diagramming. Process Stream
Mapping, a hybrid methodology that leverages the
strengths of each methodology, is introduced. The
difference between a Process Value-Added Diagram
and a Value Stream Map is explored in depth, and the
format for Process Stream Mapping is outlined.
Session Two - Connecting The Process To The
Stream
The mechanics of the Process Stream Mapping
methodology are fully delineated, and a model is
presented. Participants begin to transform the existing
Process Value-Added Diagrams (from the entry level
Certificate) into a Process Stream Map.
Session Three - - Work Cell Lean Layout Practices
As the Process Stream Map is developed, opportunities
to apply Lean Layout Practices become apparent. This
session explores the use of Lean Layout Practices at
the Work Cell level that are integral to implementing a
Lean Process Stream.

Session Six - Pacing The Lean Process Stream

The use of the emerging Lean Practice of Pacemaker
Pulled Production, as well as the pitfalls and difficulties
of implementation, are examined. Teams incorporate
Pacemaker Pulled Production into their Process
Stream Maps and Lean Factory Layout and Flow
implementation.

Session Seven - On Site Application Of Lean

Factory Layout And Flow Practices
During the seventh week, company teams complete
their Process Stream Maps and Lean Factory Layout
and Flow improvements begun in prior Sessions. The
instructor will be available during the scheduled class
time for team or individual appointments pertaining to
their Process Stream Mapping and Lean Factory
Layout and Flow improvements. Topics are revisited as
requested by company teams.
Session Eight Presentation Of Process Stream
Maps And Lean Factory Layout And Flow
Presentations
In Session Eight, each company team will present their
before and after Process Stream Map incorporating
Lean Factory Layout and Flow improvements to other
participants for review and feedback. Effective
presentation techniques are emphasized.

Session Four - Work Cell Lean Flow Practices

The opportunities to apply Lean Flow Practices at the
Work Cell level become visible as the Process Stream
Map is developed. This session explores the use of
Lean Flow Practices at the Work Cell level that are
integral to implementing a Lean Process Stream.
Session Five - Factory Lean Layout Practices
As the Process Stream Map becomes "Leaner", the
opportunities and requirements of Lean Process
Stream Flow across the factory emerge. Teams
investigate the use of various Lean Layout Practices at
the Factory level that can be employed to develop a
Lean Flow throughout the Process Stream.

SESSION STRUCTURE
Activity Schedule Per Session
Time (Min)
30
60
15
30
30
15

Activity
Homework Review
Presentation on session topic
Break
Team exercise
Feedback on Team exercise
Assignment for following week

Copyright Performance Improvement Consulting, Inc.

All Rights reserved

LOCATION
The Lean Certificate Programs are primarily designed
to be conducted on-site to meet the extensive training
needs of a company going through a lean transition.
The certificate programs are also offered in a
classroom setting. These off-site programs are held
at the University of Illinois Multi-University Center in
Oak Brook, IL located at 1010 Jorie Boulevard.

TIME COMMITMENT
The program consists of eight three hour sessions held
one day per week. On-site programs are held at a time
that best meets a companys operational needs. Off-site
programs are usually held one day per week in the
evening.

FEE

FOR MORE INFORMATION

The University of Illinois at Chicago Center for Supply
Chain Management and Logistics in partnership with the
Center for Enterprise Development, provides a complete
and customized education process for the Lean
Transformation.
Programs are offered at your company where they can be
tailored to your workplace need or at the University of
Illinois Multi-University Center in Oak Brook, IL. In addition
to the series of Lean Performance Certificates, Lean
Performance Workshops and American Lean Seminars are
also offered.
For more on any of our Lean Performance Programs,
please contact Ed Allfrey at the Center for Enterprise
Development, 630.472.9300 x16, lean@ced-uic.com or
visit our website at www.ced-uic.com/leancertificate.

On-site programs: Pricing is based on the

number of participants per company. There is
a minimum fee required. Please call regarding
on-site pricing.
Off-site programs: $2,500.00 per participant.
To request more information
Phone: 630.472.9300 Fax: 630.472.9301 E-mail: lean@ced-uic.com
Mail: Center for Enterprise Development, 1010 Jorie Boulevard Suite 108, Oak Brook, IL 60523

CERTIFICATE IN LEAN FACTORY LAYOUT AND FLOW

Name ______________________________________________________________________________
Company_______________________________________ Position______________________________
Address _____________________________________________________________________________
City ___________________________________ State _______________ Zip Code _______________
Phone _______________________ Fax ____________________ Email _________________________
I am interested in the following Lean Certificate Programs
____Lean Operations Principles, Tools, and Practices
____Planning and Managing the Lean Transformation
____Lean Factory Layout and Flow
____Lean Performance ERP Project Management
____Lean Office Layout and Flow
____Lean Commerce
____I am interested in an on-site program. We will be training #____employees.
____I am interested in your next off-site offering. We have #_____ employees interested in attending.