Lean Manufacturing Training

Who is it for?

Teams, managers and transformation teams new to lean thinking.

Learning focus

Distinguish customer value from waste and view processes through the lens of flow.

Topics covered

• The Philosophy of Lean Thinking
• Lean Manufacturing Principles
• Mura, Muri, Muda
• Toyota Principles

Who is it for?

Production, quality, engineering and shop-floor teams.

Learning focus

Relate workplace organisation, standardised work and flow to your own work area.

Topics covered

• 5S and the Visual Factory
• Standardised Work
• SMED
• Kanban and Pull Systems

Who is it for?

Production, planning, logistics and improvement teams.

Learning focus

See material and information flows together and learn current- and future-state mapping.

Topics covered

• Value and Value Streams
• Current-State Mapping
• Waiting, Inventory and Flow Analysis
• Future State and Implementation Plan

Who is it for?

Leaders at every level and improvement teams.

Learning focus

Define problems, investigate root causes and follow up countermeasures.

Topics covered

• Kaizen and Continuous Improvement
• A3 Reporting
• Employee Involvement
• PDCA
• Fishbone Diagram (Ishikawa)

Who is it for?

Warehouse, logistics, planning and production teams.

Learning focus

Identify flow losses in storage and material supply.

Topics covered

• Lean Logistics and Material Flow
• FIFO – LIFO
• FLRS – Dynamic Location Management

Who is it for?

Support functions, process owners and office teams.

Learning focus

Make information flow visible and improve the standardisation of everyday work.

Topics covered

• Process Mapping
• Standardisation Techniques
• Work Allocation and Scheduling
• Lean Office Practices

Who is it for?

Team leaders, department managers and transformation leaders.

Learning focus

Bring Gemba, problem-solving and people development into everyday leadership behaviours.

Topics covered

• Lean Leadership
• Gemba Walks
• Lean Culture

Who is it for?

Senior management, department managers and strategy teams.

Learning focus

Connect strategic priorities with daily improvement activities.

Topics covered

• Hoshin Kanri
• KPIs
• Transformation Roadmap

Who is it for?

Managers, team leaders and internal trainers.

Learning focus

Learn to progress towards a target condition through small experiments and question-based coaching.

Topics covered

• Current Condition and Target Condition
• Obstacles and Small Experiments
• Improvement Kata
• Coaching Dialogue

Who is it for?

Maintenance, production and engineering teams, and equipment owners.

Learning focus

Develop a shared understanding of equipment losses and improve maintenance practices.

Topics covered

• Equipment Losses
• OEE
• Autonomous Maintenance
• Planned Maintenance

Who is it for?

Planning, production, sales and logistics teams.

Learning focus

Assess the relationship between demand, capacity, pull systems and production flow.

Topics covered

• Demand and Capacity
• Pull Systems
• Production Levelling
• Visual Planning and Monitoring

Who is it for?

Production, quality and engineering teams.

Learning focus

Develop the ability to detect, stop and prevent defects at their source.

Topics covered

• Building Quality into the Process
• Jidoka
• Poka-Yoke
• Standardised Work and Problem-Solving

Who is it for?

Shift supervisors, team leaders and aspiring shop-floor leaders.

Learning focus

Develop a shared approach to daily shop-floor management, communication and employee development.

Topics covered

• Daily Management
• Visual Monitoring and Communication
• Problem-Solving
• On-the-Job Development

Who is it for?

Production and planning teams, industrial and process engineers, shop-floor leaders and continuous improvement specialists.

Learning focus

Break work into observable steps, measure under representative conditions and classify losses. Assess methods, quality and ergonomics together, and use standard time, capacity and workforce calculations to inform management decisions.

Topics covered

• Work systems, workflow analysis and method improvement
• Work elements, measurement points and time-study preparation
• Data collection using stopwatch studies, video and work sampling
• Representative observations, measurement adequacy and abnormal cycles
• Performance rating, basic time and standard time
• Separating rest allowances, additional time and lost time
• Ergonomics, workstation layout and standardised work
• Capacity, workload and demand-based workforce requirements
• Bottleneck analysis, work allocation and line balancing
• Productivity indicators and before-and-after comparisons

Who is it for?

Production, maintenance, engineering and planning teams; tool-setting specialists and shop-floor leaders.

Learning focus

Make changeover activities visible and distinguish internal tasks that require the machine to stop from external tasks that can safely be performed while it runs. Reduce changeover time by converting suitable internal tasks into external tasks and simplifying the remaining steps.

Topics covered

• The SMED approach and setup losses
• Observing the current changeover process and analysing times
• Separating internal and external setup activities
• Converting internal setup into external setup
• Preparing tools, materials and equipment in advance
• Reducing adjustments, fastening work and unnecessary motion
• Safe work allocation and parallel activities
• Standard changeover steps and checklists
• Monitoring improvements in time, quality and safety