20 weeks
1 session per week
4 hours per session
Total Class:  80 hours


This course is designed to provide practical knowledge and tools to improve factory operations and to aid in continuing with your Lean manufacturing efforts.  The participants use highly interactive learning methods to introduce the concepts and skills of Lean.

The target audience includes: Managers, supervisors, engineers, operators, and support staff.  After completing the course, the participants will be able to demonstrate their ability to determine the necessary steps to start the organization’s Lean Transformation, describe and identify the eight wastes, and develop and carry out a Lean action plan.

Recommended Prerequisites




  • Course Introduction and Overview
  • Defining Quality
  • Defining Lean
  • Lean Methodology
  • Overview of Toolkit

Effective Communication

  • Listening
  • Giving and Receiving Feedback
  • Resolving Communication Conflicts
  • Problem Solving

Visual Workplace and 5S Strategy

  • Brainstorming Visual Workplace Tools
  • Standard Work Exercise
  • 5S Process Review

Lean Tools

  • The Traditional Factory
  • Definition of the 8 Wastes
  • Value-Added and Non-Value-Added Activities
  • Workplace Organization
  • Cellular Layout
  • Batch and Queue Processing
  • Push vs Pull Systems
  • Takt Time
  • Kanban System

Theory of Constraints

  • The five focusing steps
  • Types of constraints
  • Buffers

Problem Solving

  • Root Cause
  • Corrective Action
  • Poke Yoke

Batch to Lean Workplace Layout

  • Basic Flowcharting and Process Mapping
  • Value Stream Mapping
  • Spaghetti Diagrams
  • Continuous Flow Requirements
  • Pull Production Tools
  • Using a checklist for 5S

Team Selection and Process Mapping

  • Assign Teams based on Company Requirements
  • Tool: Brainstorming Team Names and Multivoting
  • Project Selection or Assignment
  • Criteria Selection Grid

Team Development and Meeting Management

  • Communication Skills
  • Team Development Theory
  • SWOT analysis of assigned Teams
  • Meeting Management Process: 7 important steps
  • Hold Team Meetings and Analyze Process
  • Project Updates

Time Management

  • Understand reasons for poor time management
  • Effective meetings
  • Develop reasons for making choices
  • Prepare overall goals, strategies, and plans
  • Learn techniques for using time efficiently
  • Project Updates

Value Stream Mapping and the Current State

  • Selected Team Process will be analyzed using VSM Tools
  • Examine and Challenge every Step
  • Analyze wait times
  • Project Updates

Value Stream Mapping and the Future State

  • Low Hanging Fruit Analysis
  • Balance Chart
  • Takt Time
  • Standard Work Application
  • Project Updates

Kaizen Event Planning

  • Brainstorming
  • Priority Grid
  • Disaster Plan
  • Kaizen Checklist


Employee Application Employer Application