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4-day CertificatioN Program:
Certified lean-Agile Transformation Leader


Schedule & Registration



What Makes this Certification Unique?



The apparel industry’s approach to Lean has long been constrained by a lack of analytical depth, strategic alignment, and cross-functional engagement—often relying on a single Lean Champion isolated from financial strategy, engineering integration, and real-time execution. Most Lean Black Belts lack the competencies needed to innovate and design solutions that address the industry's intensifying challenges. They often fail to understand the key drivers that impact tactical success factors critical to achieving core objectives. Instead, they remain limited by traditional Lean programs that simply replicate Toyota’s Production System (TPS), designed for capital-intensive industries like automotive manufacturing, while overlooking the unique demands of labor-intensive sectors like apparel.


Without deep expertise in strategic and tactical planning, cost optimization, product family segmentation, and the key drivers of competitiveness, experts struggle to close business performance gaps and adapt to rapidly evolving industry challenges. The failure to tailor and align Lean with Agile dynamic manufacturing principles, AI-driven real-time decision-making, and innovative, cost-effective production structures has left many manufacturers stagnant—unable to unlock true Lean-Agile capabilities, adaptability, embedded sustainability, responsiveness, or scalable operations for long-term resilience and competitive success. This is the improvement strategy the apparel industry should have embraced long ago, yet it has continually overlooked the true foundations of world-class manufacturing.


The Lean-Agile Excellence Expert stands apart—surpassing conventional Lean Black Belt certification and equivalent programs such as Lean Six Sigma Black Belt by equipping leaders with the expertise to seamlessly integrate strategy with execution, drive systemic agility, and engineer lasting competitive advantage. This certification program develops future experts with advanced competencies to strategically manage, coordinate, and lead dynamic engineering, smart support teams, and an agile, adaptive workforce—fostering innovation, optimization, continuous learning, and the transformation of apparel manufacturing into a high-performance, future-ready ecosystem.


Under the leadership of Dr. Charles Dagher, this program develops leaders’ ability to strategize, organize, guide, and refine the future of Apparel 4.0. Participants will gain expertise in strategic leadership, engineering-driven agility, AI-powered real-time adaptability, and essential skills to align cross-functional teams, optimize operations, and build an adaptive workforce. By integrating resilient structures, flexible processes, and true agility, this certification equips leaders to drive apparel manufacturing toward world-class excellence.


Join us to master the strategies needed to unlock competitiveness and shape the future of Apparel 4.0.



WHY THIS CERTIFICATION STANDS OUT

  • First-of-Its-Kind Program – Bridges the critical expertise gap by integrating deep analytical capabilities, strategic alignment, and cross-functional synergy to drive true Lean-Agile transformation.
  • Competitiveness-Centered Approach – Moves beyond the misapplication of Toyota’s TPS by leveraging advanced Agile analytics, data-driven decision-making, and adaptive execution models tailored for apparel manufacturing..
  • Expert-Led by Dr. Dagher – A pioneer in Lean-Agile for the apparel industry, delivering immediate, measurable impact.
  • Hands-On Learning – Real-world case studies, interactive simulations, and custom implementation roadmaps.
  • Fast-Track Results – Drives measurable transformation in days and weeks—not months or years.




The Lean-Agile Transformation Leader is responsible for managing, organizing, guiding, and monitoring the overall transformation journey. This role ensures that Lean-Agile principles into long-term business objectives, ensuring seamless execution by aligning the factory’s operational and strategic framework with tactical actions while continuously adapting and refining the transformation roadmap. Managing governance structures, cross-functional teams, and key milestones guarantees a well-coordinated transformation process. A robust tracking system enables real-time adjustments by identifying gaps in the improvement initiatives. Once systems and concepts are designed, tested and standardized, the leader designs a scalable transformational model that adapts to the evolved systems while maintaining core principles embedded as a strategic pillar, ensuring sustained competitiveness and industry leadership while preventing regression to traditional models.



Certification Program Outline & Target Audience



The certification program is structured into two phases, each consisting of two consecutive days, allowing participants the necessary time to absorb, apply, and internalize the gained knowledge effectively.



Day 1 - Foundations of Lean-Agile Manufacturing





Session 1: The Evolution of Lean & Agile Manufacturing

  • From Mass Production to Lean to Agile: A Paradigm
  • Shift Lean vs. Agile Manufacturing: Strengths,
  • Limitations & Synergy Why Lean-Agile Integration is Key for Competitive Advantage
  • Aligning Profitability Drivers with Tactical Execution
  • External & Internal Factors Impacting Competitiveness

Session 2: Rethinking Lean for Apparel Manufacturing

  • Why Traditional Lean Fails in the Apparel Industry
  • Tailoring Lean Principles for Labor-Intensive Apparel Manufacturing
  • Macro & Micro Waste: The Hidden Barriers to Future Competitiveness
  • Customizing Just-in-Time (JIT) for Apparel-Specific Workflows Case
  • Study: Evolution of Lean in the Apparel Industry & Key Lessons

Session 3: Agile Manufacturing – Enabling Flexibility & Speed

  • The 14 Core Principles of Agile Manufacturing
  • Smart Factories & Digital Technologies in Lean-Agile Transformation
  • Agile’s Role in High-Mix, Small-Batch, and Rapid Product Diversification Case Study: How Zara’s Fast Fashion Model & Tesla’s Dynamic Manufacturing Drive Agility

Session 4: Lean-Agile Synergy – Merging Efficiency with Adaptability

  • Why Lean Alone Is Insufficient in Today’s Volatile Market
  • How Agile Complements Lean in Demand-Driven Operations
  • The Lean-Agile Framework for Manufacturing: Waste-Free, Disruption-Free, Delay-Free Systems
  • Group Exercise: Identifying Lean-Agile Integration Opportunities in Your Organization


DAY 2 – Strategic Execution Driven Transformation





Session 5: Tactical & Strategic Planning for Agile Manufacturing

  • Aligning Lean-Agile Transformation with Corporate Vision
  • Tactical Strategies for High-Mix, Low-Volume Production
  • Establishing Agility-Driven Performance Metrics for Efficiency & Responsiveness
  • Governance Models for Continuous Monitoring & Adaptive Process Refinement

Session 6: Engineering-Driven Transformation & Smart Support Teams

  • Engineering as the Backbone of Lean-Agile Transformation
  • The Role of Smart, Dynamic Support Leadership in Sustainable Systems
  • Simulation-Based Problem-Solving for Lean-Agile Execution
  • Management & Engineering Simulations: Keeping Transformational Goals on Track
  • Value Management & Engineering: Maximizing Resource Utilization & Adaptability
  • Flexible Workflows for Enhanced Productivity & Rapid Market Responsiveness

Session 7: Agile Supporting Systems & Responsive Manufacturing Structures

  • Product Family Routing Strategies for Manufacturing Segmentation & Cross-Functional Collaboration
  • Optimizing Manufacturing Platforms for Agility in High-Mix, Low-Volume Production
  • Proactive Disruption Elimination for Zero-Efficiency Loss Operations
  • Rapid Order Changeover Strategies: Seamless Transitions Without Downtime
  • Intelligent Adaptive Workflows: Merging Efficiency, Flexibility & Resilience


DAY 3 – Advanced Lean-Agile Strategies





Session 8: Workforce Agility & Culture Transformation

  • Developing Cross-Trained, Multi-Skilled Workforces for Adaptive Manufacturing
  • Lean-Agile Operating Systems: Structuring Training for Future-Ready Roles
  • Workforce Adaptability Strategies for Dynamic Production Environments
  • Hands-on Exercise: Designing & Integrating a Lean-Agile Workforce Model

Session 9: Measuring Lean-Agile Performance & Continuous

  • Improvement Key Performance Indicators (KPIs) for Lean-Agile Success
  • Continuous Innovation vs. Continuous Improvement
  • Gemba Walks vs. Gemba-Led Disruption Elimination
  • Hands-on Exercise: Developing a Lean-Agile KPI Dashboard

Session 10: Overcoming Challenges in Lean-Agile Adoption

  • Common Roadblocks & Pitfalls in Lean-Agile Transformation
  • Managing Resistance to Change: Leadership Strategies for Team Buy-In
  • Awareness & Knowledge Transfer Techniques for Continuous Learning & Adaptability
  • Case Study: Success Stories & Lessons from Failed Lean-Agile Implementations

Session 11: The Cockpit – Driving & Managing Transformation Roadmap Progress

  • Scaling Lean-Agile Transformation from Pilot Success to Full Factory Implementation
  • Hoshin Kanri & Simplified Project Management for Strategic Execution
  • Step-by-Step Implementation Planning for Sustainable Transformation
  • KPI Dashboards & Performance Monitoring for Agile Excellence.


DAY 4 – Practical Application & Simulation





Session 12: Final Application & Simulation

  • Tactical & Operational Planning Exercise: Aligning Core Objectives with Execution
  • Custom Lean-Agile Roadmap: Developing a Strategy for Organizational Transformation
  • Key Focus Areas for Sustainable Change & Strategic Execution
  • Simulation: Evaluating Potential Outcomes Based on Case Studies & Key Assessment Findings
  • Final Reflections & Certification Ceremony




TARGET AUDIENCE

  • Factory Directors & Plant Managers
  • Operations & Production Leaders
  • Industrial & Manufacturing Engineers
  • Lean-Agile Transformation Leaders
  • Consultants & Trainers
  • Lean Black Belt Experts
  • Lean & Continuous Improvement Leaders
  • Innovation & Technology Experts
  • Anyone Interested in Learning


Core Competencies Developed



This program equips participants with the expertise to lead, strategize, and execute transformation through advanced Lean-Agile methodologies. Key competencies include:



Strategic Lean-Agile Leadership & Execution

  • Integrating Lean and Agile principles for scalable, high-performance manufacturing.
  • Aligning corporate strategy with operational execution using Hoshin Kanri.
  • Structuring goal-driven initiatives for long-term competitiveness.

Advanced Project Management, Tracking & Tactical Adjustments

  • Mastering agile project execution to align strategic objectives with real-time operations.
  • Implementing adaptive tracking models for continuous monitoring and dynamic adjustments.
  • Driving Hoshin Kanri-based execution frameworks to ensure goal alignment.
  • Managing cross-functional collaboration for seamless integration across teams.

Data-Driven Decision-Making & Performance Optimization

  • Utilizing predictive analytics to anticipate demand fluctuations and optimize workflows.
  • Applying real-time performance tracking tools for agility and responsiveness.
  • Engineering dynamic manufacturing and management models beyond Toyota’s TPS limitations.

Manufacturing Process Agility & Smart Execution

  • Driving small-batch, high-mix production strategies for rapid response to market needs.
  • Implementing agile execution systems to eliminate bottlenecks and disruptions.
  • Establishing real-time order responsiveness and workflow adaptability.

Agile Workforce & High-Impact Team Leadership

  • Developing cross-functional, high-performance teams for agility and responsiveness.
  • Training leaders to guide teams through uncertainty and complex transformations.
  • Embedding a culture of adaptability, ownership, and accountability.
  • Establishing structured coaching and mentoring frameworks for skill evolution.

Technology-Driven Competitiveness & Industry 4.0 Mastery

  • Leveraging digital twins, AI, and automation for real-time decision-making.
  • Designing smart factories with Lean-Agile Industry 4.0 integration.
  • Applying intelligent workflow systems for end-to-end digital execution.

Performance Management, KPI Tracking & Continuous Improvement

  • Defining and tracking Lean-Agile KPIs to measure transformation impact.
  • Scaling pilot successes into factory-wide transformation roadmaps.
  • Implementing continuous improvement governance models to sustain growth.




Industry-Recognized Certification





Participants who successfully complete the program will earn the Lean-Agile Transformation Leader certification, validating their ability to lead, guide, and execute comprehensive transformational initiatives that drive competitiveness in modern apparel manufacturing.



GENERAL INFORMATION

Included Amenities: Two tea coffee breaks and Lunch provided throughout the program.



Accreditation Document





This accreditation document defines the strategic role and impact of a Lean-Agile Transformation Leader in the evolving apparel industry. It serves as a guidance framework for industry leaders and decision-makers, outlining how certified professionals will drive competitiveness in the Apparel 4.0 era, enhance sustainability and adaptability through smart manufacturing strategies, and integrate workforce agility with cutting-edge analytical methodologies. This document formally positions certified participants as key industry leaders, ensuring their expertise is recognized as essential for shaping the future of apparel manufacturing.



Shaping the Next Generation of Professionals




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