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Lean Certification Awards

 

 

 

This document explains the process by which a garment manufacturing organization can obtain certification from DCG as a Certified Lean Garment Manufacturing Organization.

 

 

 

 

 

 

1.             Process Steps

·        The applicant organization submits an application form to DCG.

·        A representative from DCG visits the applicant organization in order to:

  • View the facility.

  • Assess how far organization has come on its Lean journey.

  • Request any clarification arising from initial application.

  • Enables applicant to present key points of their proposed or existing Lean program.

·        Senior management will first complete an independent assessment, without consultant intervention, analyzing the organization of three aspects of their operations: processes, infrastructure and leadership, followed by a one-day workshop facilitated by a DCG representative.  The DCG Facilitator engages with the client’s executive team in strategic discussions on the results of the assessment, focusing on elements that add value and processes that contribute to added-value.  The outcome of the Facilitation will be some/all of the following:

 

• Development of a top level action plan

• Identification of strategic drivers

• Identification of strategic core processes

• Selection of an internal Lean Champion and a Core Lean Team

• Identification of team members for further education/training

• Identification of pilot processes for Lean implementation

• Development of strategic metrics required to measure success

 

·        Two in-house customized projects are undertaken over a three-month period as part of the formal certification process.

·        Strategic measurements for the organization’s Lean Program are clearly visible in the facility and measured against on a monthly basis.

·        Final certification review takes place within the first six months. DCG then awards certification to the successful organization.

 

2.            Annual Reviews

DCG will perform annual on-site reviews to audit and benchmark Lean performance and assess the organization’s adherence to the overall game plan. Full training and educational records will need to be maintained by the organization.

 

3.            Period of Certification

An organization’s certification will be valid for two years, providing the organization makes no significant changes to its program in the interim. Re-certification will be required at this stage, but would typically be provided for in the annual review process.

 

4.            Certification Privileges

DCG will issue Lean Certified Organization awards to those organizations that successfully complete their program. The organization’s logo will be placed on the certificate awarded.   DCG are the appointed representatives of TSS  (Toyota Sewing System) when facilitating the above program.

 

5.            Lean Transformation Program

The complete transformation program is composed of 18 training and application sessions.

 

 6.     Organization Awards

The following awards will be given by the DCG Certification Program each time an appropriate level of competency has been demonstrated:

 

Basic Lean Corporate Award White Belt

This competency refers to a corporate awareness of Lean philosophies and principles.  It also requires basic knowledge and practical experience of the application of basic Lean tools and practices including the “Pull Production” concept and the identification of Waste at corporate and manufacturing level.

 

Proficient Lean Corporate Award Green Belt

This award is given when the company is able to apply specific Lean principles and tools across its core functions on a practical level.  This is achieved when staff members obtain the appropriate education and have successfully implemented the associated customized work assignments through several Point Kaizen and Flow Kaizen events.

 

Advanced Lean Corporate Award Black Belt

This award is made when a company is able to develop, implement and lead a Lean transformation strategy comprised of several continuous improvement milestones.  The organization’s Champion, appointed from within and educated to Black Belt Standard, must have previously demonstrated annual cost savings and shortened lead times averaging 10-20% since beginning the Lean project.

 

World Class Lean Corporate Award Master Black Belt

This award is made when the company is able to:   

  • Achieve significant ongoing improvements across the facility after Lean transformation.

  • Meet or exceed key performance measurements after Lean transformation.

  • Sustain a flexible, efficient and sustainable Lean program supported by all staff members.

  • Demonstrate sustained commitment to applying Lean practices across all aspects of its operation.

 

Organizations achieving this level will be considered as best-in-class Lean examples throughout the national and international manufacturing networks in which they operate.
 



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