Lean & Quality training for manufacturing

Certified means proven on the floor.

Lean and Quality training for manufacturing plants. Nobody is certified for finishing a class. Certification comes only after a rubric sign-off on the job and a result held for weeks.

Request a demo link → See the simulators

Built by Youssef Barnetche, Operational Excellence, Lean & Quality Leader

One-Piece Flow: four people, one unit between them.

LEGO Yamazumi: one car built at station 3, timed against takt.

SKILLS MATRIX · 1.1Tiered daily meetingsTeam lead, Line 3 · example, fictional

LearnQuiz 88%

Passed

ProveDMS-R01 rubric

Pass

Sustainheld for 8 weeks

Wk 5/8

Current level 2 · ProvenLevel 3 only when the Sustain target is held.

Team members

Build it, feel the wait, fix your own station.

LEGO Yamazumi →One-Piece Flow →

Team leads & supervisors

Run the line to takt and lead the daily conversation.

Line Balance Board →SMED Changeover →

Engineers & quality

Prove the process and the fix with data and records.

Process Validation →Investigation & CAPA →

Managers

See the result in dollars, capacity and risk.

Process Capacity Board →Constraint Dice Game →

Learn stage · the simulators

Teams don’t watch slides. They run the line.

39 browser simulators, no install. Teams move real work on a chart, watch the numbers change, and compare their plan with two coach proposals. Pick one to look inside.

Lean · Flow & line balance

Lean · Changeover, leveling & pull

Lean · Equipment & statistics

Lean · Problem solving & office

Lean · Warehouse & supply chain

ProvenFloor Quality

ONE-PIECE FLOW

One-Piece Flow Trainer

U-cell with in-process kanban

What teams do: Set the crew, the IPK size and the work split, then watch the cell run: who waits, who slows the line, where parts stack up.
What the screen shows: A 4-person catheter-assembly cell running with IPK = 1 (5-second clip)

1 / 25

ProvenFloor Quality

One trainer, four industries

Every Quality simulator opens with a case dropdown. Pick the case closest to your plant and the whole trainer changes with it: records, data, the right answers and the rubric checks. Each trainer carries 2 medical-device cases, 1 biotech case and 1 aerospace or automotive case.

Trainer	MED	BIO	AUTO	AERO
Investigation & CAPA Trainer	Catheter bond · pull strength IV set label mix-up · complaint	Lyophilized reagent · moisture OOS	—	Aerospace bracket · oversize bore
Root Cause Trainer · Version B	SpO2 sensor cable opens under flex Wrong syringe in a dressing tray	Enzyme activity OOS after freezer storage	—	Under-aged fittings found by the customer
Change Impact Trainer	Dressing tray · 5S re-layout Catheter tubing · new resin supplier	Media bags · new single-use supplier	Seat-belt bracket · weld cell move	Flap hinge fitting · new machine
Process Validation Simulator	Tray lid sealer IV filter weld (PQ built to fail)	Vial crimp capping	Brake hose crimp	Bracket heat treat
Spot the GDP Error	Shaft extrusion · in-process check sheet	Seed train passage · batch record	Weld cell W-3 · start-of-shift check	—

MED medical device BIO biotech AUTO automotive AERO aerospace. All cases are fictional.

Built into every simulator

The result does not stop at the chart. Every simulator turns it into money, into owned actions, and into a conversation each level can have. Shown here from the Line Balance Board.

Business case

From seconds to dollars

Plant numbers go in once. The simulator compares today with the team’s plan or a proposal, then offers two honest options: bank the savings, or spend the capacity on growth.

5 → 3 operators per shift · $3.19 → $1.49 per unit · $366,240 a year

Business case panel from the Line Balance Board

Action plan

Every change has an owner

Each element the team removed, moved or improved becomes a row: action, idea, owner, time before and after, cost. Rows without an owner are flagged. One click copies it into Excel.

16 actions · 9 still without an owner · 217 → 159 seconds per unit

Action plan table from the Line Balance Board

Role lens

Same result, three conversations

The team member hears about their own job: the heaviest station, the walking, the overtime. The supervisor hears about the daily plan; management about capacity and people. Each tab ends with questions to ask in the room.

Team Member · Supervisor · Management

Three ways to workSimple exercise for first-timers, guided stages for class, free play for experts.

Answers stay lockedCoach proposals open only after teams try their own plan.

Live class boardIn facilitated sessions, each team posts its plan and the board ranks them as they come in.

Practice checkScored item by item against the sign-off rubric the evaluator will use.

Coach’s notesDefinitions, formulas, an analogy and a 5-step class plan for the trainer.

See all 39 simulatorsby curriculum area

Foundation 11

Warehouse & supply chain 3

Lean Warehouse Trainer
Lean Logistics Trainer
Lean Supply Chain Trainer

DMS · Daily management 3

Tier Meeting Simulator
LPA Practice Audit
Spot the Abnormality

WF · Waste & flow 6

EQ · Equipment & quality 5

OEE Six Big Losses
Andon Response Simulator
SPC Reaction Trainer
Gage R&R Calculator
DOE Simulator

CI · Continuous improvement 3

Kaizen Charter Trainer
Idea Board Trainer
Root Cause Trainer (shared with Quality)

LO · Lean office 4

Swimlane Map Builder
Office Waste Hunt
WIP Limit Simulator
Faulty Form Fixer

Quality · Regulated plants 4

Investigation & CAPA Trainer
Change Impact Trainer
Spot the GDP Error
Process Validation Simulator

Every case is fictional, with no real company data. Screens are taken from the current builds.

The model

Learn, Prove, Sustain

Most of the effort goes into practice and real work. Every stage has written criteria an evaluator can see or measure.

~10%

~20%

~70% · on the job

Learn

Training app, short reading and a quiz.

Judged by: Quiz score of 80% or higher

Prove

Exercise, simulation or observed task on real work or real records.

Judged by: Sign-off rubric scored by a certified evaluator

Sustain

A real assignment with a target, repeated over weeks.

Judged by: A measured result held for a set period

The 70/20/10 split comes from Lombardo & Eichinger (Center for Creative Leadership). We use it as a design rule, not as a measured effectiveness rate.

0Not trained—

1LearnedQuiz passed

2ProvenRubric passed

3SustainedSustain target met

4Teaches & evaluatesTrained others, calibrated as evaluator

Levels feed your skills matrix. A Sustain target that slips moves the person back to Level 2 until it recovers. Rubric skills are rechecked every 12 months.

Two suites, one standard

Lean and Quality, built the same way

ProvenFloor Lean

Daily management, flow, equipment, improvement and office processes, rolled out by phase with a gate before each one.

40Topics

34Rubrics

5Phases

DMSDaily Management System5
WFWaste & Flow6
EQEquipment & Quality6
CIContinuous Improvement5
LOLean in Business Processes6

Builds on 12 foundation topics: one-piece flow, standard work, SMED, kanban sizing, heijunka, 5S, poka-yoke, A3, Yamazumi, inbound/outbound logistics, supply chain and warehouse.

ProvenFloor Quality

The quality-system work a regulated plant runs every day, from the first containment to the inspection room. Built for medical devices.

23Topics

21New rubrics

5Phases

IVInvestigations & Problem Solving5
CANonconformance & CAPA5
DCChange Control & Documentation3
RVRisk & Validation6
ARAudit & Readiness4

ISO 13485:2016FDA QMSR · 21 CFR 820ISO 14971:2019ISO 19011ISO 2859-1

Try it

Score a real sign-off rubric

This is the model every rubric follows. Tap an item to mark it failed and watch the result apply the written scoring rule. Two evaluators watching the same meeting reach the same answer.

Rubric DMS-R01 v1.0

Run a Tier 1 start-of-shift meeting

Observable only"Board updated by 7:15", never "good meeting". Each item says how it is checked: timed, observed, board, record or asked.

Calibrated evaluatorsNew evaluators score alongside a certified one and must match on every Critical item before they score alone.

VersionedEvery rubric has a version. When the standard changes, the version changes and affected people are rechecked.

Delivery

Where your training records live

The training content is the same in every tier. What changes is where the data is kept. Every tier is delivered remotely.

Demo Temporary · our platform

A private link for your company with an expiry date
Forward it to your review panel while it is active
Data entered is deleted after the demo ends

Standard Kept · our platform

A separate space for your plant
Progress and scores kept and exportable
Live class board for facilitated sessions

Premium Your LMS or your servers Main offer for regulated plants

SCORM or cmi5 package uploaded to your LMS
Or an LTI 1.3 link with scores sent back
Self-hosted option on your own servers

Regulated plants

Under ISO 13485 clause 6.2, training records are quality records. When ProvenFloor plugs into the LMS you already validated, that system stays the record. We deliver the training and report the score.

Contact

Request a demo link

Email your plant type, the topics you want to see and who will review them.
You get a private link for your company with an expiry date.
Run the simulators, or book a live facilitated session online.

contact@provenfloor.app

LinkedIn: linkedin.com/company/provenfloor

Founder

Youssef Barnetche

Operational Excellence, Lean & Quality Leader

Lean Six Sigma Black Belt · MBA · B.S. Industrial and Systems Engineering. ProvenFloor grew out of the workshops he runs on the floor.

Connect on LinkedIn linkedin.com/in/ybarnetche/

24 years of engineering & operations, 18+ in medical devices, delivering Lean and Quality results:

18 → 11 dayslead time

+41%productivity

−77%critical quality risk

Medical device cleanroom team at a production board, and an industrial powder coating and curing conveyor line

Plan with the team, prototype the line in cardboard, build the real work cells

Delivered remotely. ProvenFloor is operated from Baja California, Mexico.