Lean Management: Lean Management in Manufacturing Training Course

Course Code



14 hours (usually 2 days including breaks)


  • An interest in developing people, improving efficiency, and eliminating waste within the organization


  • Business managers
  • Quality assurance managers and consultants


Lean Management is an approach to running an organization. It promotes a long-term view of work and a culture of continuous improvement -- seeking to continuously and systematically achieve small, incremental changes in processes in order to improve efficiency and quality.

In this instructor-led, live training (onsite or remote), participants learn how to apply Lean principles and practices within a manufacturing context and establish a culture of continuous improvement.

The training combines case activities and discussions with live, hands-on practice using the tools, metrics, and methods needed to implement Lean systems and processes. Some of the concepts covered include:

  • Determining the root cause of inefficiencies.
  • Measuring performance.
  • Realizing the continuous improvement cycle.
  • Organizing Kaizen events.
  • Instilling a mindset of Lean thinking across the organization.

Format of the Course

  • Interactive lecture and discussion.
  • Lots of exercises and practice.
  • Hands-on implementation in a live-lab environment.

Course Customization Options

  • To request a customized training for this course, please contact us to arrange.

Course Outline


  • History of Lean: The Toyota Production System

Lean Thinking

  • Organizing human activities

Benefits of Lean

  • Cash flow improvement
  • Increased capacity for revenue

Five Principles of Lean

  • Value
  • The Value Stream
  • Flow
  • Pull
  • Perfection

Types of Waste

  • Seven types of waste
  • Using the wrong metrics to measure waste

Measuring Performance

  • Observing processes
  • Understanding the key aspects of a KPI

Preparing the Enterprise for Lean

  • Creating Lean processes
  • Tracking work through Kanban
  • Overcoming resistance to change

Implementing Lean in Your Organization

  • Organizing the teams
  • Kaizen and the continuous improvement cycle
  • Developing people and partners
  • Organizing the workspace for efficiency
    • 5 S+1: Sort, Straighten, Shine, Standardize, Sustain, Safety
  • Reducing the time for equipment changeovers
    • SMED (Single-Minute Exchange of Dies)
  • Calculating the pace of production (Takt time)
  • Autonomation (Jidoka)
  • Error proofing (Poka Yoke)

Value Stream Mapping

  • Lean measurements
  • Creating current and future state maps
  • Just-in-time
  • Built-in-quality

Promoting Lean Thinking across the Enterprise

  • Tools + culture change
  • Coaching
  • Developing communication and feedback channels
  • Focusing on long-term learning

Developing Lean Leaders

  • Setting up a Lean leadership team
  • Creating a succession system

Assessing the Results of Lean

  • The Lean Maturity Matrix
  • Tracking performance
  • Benchmarking against other companies
  • Continuous monitoring and improvement

Complementary Methodologies

  • Agile and Scrum
  • Six Sigma

Summary and Conclusion



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