Lean Management Specialist Course

Lesson 1 • Origins and Evolution of Lean

Traces Lean from Toyota's production system to global adoption. Establishes historical context that frames every subsequent principle and tool.

Lesson 2 • Core Lean Principles

Introduces the five Lean principles: value, value stream, flow, pull, and perfection. Provides the conceptual framework students apply throughout the course.

Lesson 3 • Lean vs. Traditional Management

Contrasts Lean's customer-centric, flow-based model with batch-and-push management. Clarifies why Lean requires a fundamental mindset shift.

Lesson 1 • VSM Symbols and Conventions

Covers standard icons, data boxes, and flow arrows used in value stream maps. Mastery of notation ensures accurate, readable maps in later exercises.

Lesson 2 • VSM in Service and Office Environments

Adapts VSM techniques to transactional and knowledge-work processes. Extends students' mapping skills beyond manufacturing to any workflow.

Lesson 3 • VSM Metrics and Analysis

Teaches process efficiency, lead time ratio, and value-added time calculations. Quantitative analysis links map findings to measurable business impact.

Lesson 4 • Designing the Future State Map

Applies Lean design rules to create a future state with reduced waste and improved flow. Students practice translating principles into actionable map changes.

Lesson 1 • Visual Management Integration

Links 5S to visual controls such as shadow boards, floor markings, and color coding. Visual management makes abnormalities immediately obvious to all workers.

Lesson 2 • The Five S Phases Explained

Defines Sort, Set in Order, Shine, Standardize, and Sustain with practical examples. Provides the complete framework before students apply each phase.

Lesson 3 • Sustaining 5S Over Time

Addresses audit schedules, scoring systems, and leadership behaviors that maintain 5S gains. Sustainability separates lasting improvement from one-time events.

Lesson 1 • Time Observation and Analysis

Teaches time study methods to capture actual cycle times and identify variation. Accurate time data is essential for setting realistic and fair standards.

Lesson 2 • Documenting Standard Work

Covers the three standard work documents: combination sheet, job instruction sheet, and standardized work chart. Proper documentation makes standards visible and trainable.

Lesson 3 • Principles of Standard Work

Explains takt time, work sequence, and standard in-process stock as the three elements of standard work. Clarifies why standardization enables rather than restricts improvement.

Lesson 1 • Building a Daily Improvement Culture

Introduces suggestion systems, small-group activities, and leader behaviors that make improvement a daily habit. Culture change is the multiplier that scales individual kaizen gains.

Lesson 2 • Sustaining Kaizen Gains

Addresses 30-60-90 day follow-up, open-item tracking, and leader standard work to lock in improvements. Sustained gains validate the investment in kaizen events.

Lesson 3 • Executing the Kaizen Event

Guides students through the five-day kaizen event structure from observation to implementation. Hands-on execution builds confidence in leading real improvement work.

Lesson 4 • Planning a Kaizen Event

Covers charter development, team composition, and pre-work data collection for a focused improvement event. Thorough planning maximizes results within the event window.

Lesson 1 • Kanban System Design

Covers production and withdrawal kanban types, sizing formulas, and replenishment rules. Properly sized kanban loops balance inventory investment against service levels.

Lesson 2 • Flow vs. Batch Processing

Contrasts one-piece flow with batch-and-queue processing using quantitative examples. Understanding flow economics motivates the shift to pull-based system design.

Lesson 3 • Supermarkets and FIFO Lanes

Explains when to use supermarket pull vs. FIFO sequential flow and how to design each. Choosing the right pull mechanism prevents overproduction and queue buildup.

Lesson 4 • Pull System Performance Metrics

Defines fill rate, inventory turns, and on-time delivery as pull system KPIs. Metrics close the feedback loop and drive ongoing pull system refinement.

Lesson 1 • Mistake-Proofing and Poka-Yoke

Teaches poka-yoke design principles to prevent defects at the source rather than detecting them downstream. Error-proofing is the highest-leverage countermeasure for recurring defects.

Lesson 2 • A3 Report Development

Guides students through each section of the A3 report from background to follow-up. The A3 format structures thinking and communicates improvement stories concisely.

Lesson 3 • Statistical Tools for Problem Solving

Introduces Pareto charts, run charts, and control charts to quantify and monitor problems. Data-driven analysis prevents misdiagnosis and validates countermeasure effectiveness.

Lesson 4 • Lean Problem-Solving Framework

Introduces the PDCA cycle as the backbone of Lean problem solving and maps it to A3 thinking. A shared framework aligns teams and prevents jumping to solutions.

Lesson 1 • Lean Management System Design

Defines the daily management system including tiered huddles, visual boards, and leader standard work. A management system makes Lean self-sustaining rather than event-dependent.

Lesson 2 • Hoshin Kanri Policy Deployment

Explains the X-matrix, catchball process, and annual planning cycle of hoshin kanri. Aligning improvement priorities to strategy ensures Lean effort drives business results.

Lesson 3 • Lean Transformation Roadmap

Covers the five elements of a Lean transformation framework: purpose, process, people, management system, and mindset. A roadmap prevents piecemeal tool deployment without cultural change.

Lesson 4 • Measuring Lean Maturity and ROI

Introduces maturity assessment models and financial benefit quantification methods for Lean programs. Demonstrating ROI secures executive sponsorship and sustains investment.