Lean training

Lesson 1 • Understanding the Eight Wastes

Defines and illustrates the eight categories of waste (DOWNTIME). Learners develop the ability to recognise waste in real work environments.

Lesson 2 • Core Lean Principles

Introduces the five Lean principles: value, value stream, flow, pull, and perfection. These principles form the decision-making framework used throughout the course.

Lesson 3 • Lean Culture and Mindset

Examines the behavioural and cultural shifts required for Lean success. Connects individual mindset to organisational transformation outcomes.

Lesson 1 • VSM Symbols and Notation

Covers standard VSM icons for processes, inventory, information flow, and push/pull arrows. Accurate notation is prerequisite to building valid maps.

Lesson 2 • Building the Current-State Map

Guides learners through data collection and map construction for an existing process. Produces a complete current-state VSM as a baseline for improvement.

Lesson 3 • Analysing the Current-State Map

Applies waste identification and flow analysis to the completed current-state map. Learners prioritise improvement areas using data-driven criteria.

Lesson 1 • 5S in Office and Service Environments

Adapts 5S principles to digital files, shared drives, and service workflows. Bridges the gap between manufacturing origins and knowledge-work applications.

Lesson 2 • Sort and Set in Order

Covers red-tagging, item classification, and visual placement strategies. Learners apply Sort and Set in Order to eliminate clutter and reduce search time.

Lesson 3 • Introduction to 5S Methodology

Defines Sort, Set in Order, Shine, Standardise, and Sustain with practical examples. Establishes 5S as the foundation for all other Lean tools.

Lesson 1 • Principles of Standard Work

Explains takt time, work sequence, and standard in-process stock as the three elements of standard work. Connects process stability to continuous improvement capability.

Lesson 2 • Measuring and Reducing Process Variation

Introduces time observation, cycle-time data collection, and basic statistical thinking. Learners identify variation sources and prioritise stabilisation actions.

Lesson 3 • Creating Standard Work Documents

Guides learners through completing standardised work charts, combination sheets, and job breakdowns. Produces ready-to-use documents for training and auditing.

Lesson 1 • Push vs. Pull System Concepts

Contrasts push scheduling with demand-driven pull logic using real examples. Establishes why pull systems reduce overproduction and inventory waste.

Lesson 2 • One-Piece Flow and Batch Reduction

Demonstrates how reducing batch sizes accelerates flow and exposes quality problems. Learners apply batch-reduction techniques to their own process contexts.

Lesson 3 • Kanban System Design

Covers kanban types, card calculation formulas, and replenishment rules. Learners size and configure a kanban loop for a defined process segment.

Lesson 1 • Facilitating the Kaizen Event

Provides facilitation techniques for each day of a typical three-to-five-day event. Learners practise managing team dynamics, idea generation, and rapid testing.

Lesson 2 • Kaizen Philosophy and Types

Distinguishes point kaizen, flow kaizen, and system kaizen with appropriate use cases. Grounds improvement activity in the Lean principle of pursuing perfection.

Lesson 3 • Kaizen Event Planning and Preparation

Covers scope definition, team selection, data collection, and pre-event logistics. Thorough preparation is the primary driver of kaizen event success.

Lesson 1 • A3 Thinking and Report Writing

Teaches the A3 format as a structured thinking and communication tool. Learners complete an A3 report from background through follow-up sections.

Lesson 2 • Root Cause Analysis Techniques

Covers 5 Whys, fishbone (Ishikawa) diagrams, and fault tree analysis for deep root cause identification. Learners practise each technique on realistic process scenarios.

Lesson 3 • Countermeasure Development and Verification

Guides learners through generating, selecting, and testing countermeasures against root causes. Verification methods confirm that solutions are effective and sustainable.

Lesson 1 • Sustaining a Lean Culture Long-Term

Addresses leadership behaviours, coaching systems, and recognition practices that sustain Lean culture. Learners identify organisational barriers and design mitigation strategies.

Lesson 2 • Lean Metrics and Performance Management

Defines key Lean metrics: lead time, OEE, first-pass yield, and cost of poor quality. Learners design a balanced scorecard that drives the right behaviours.

Lesson 3 • Hoshin Kanri Policy Deployment

Introduces Hoshin Kanri as a method for aligning strategic goals with daily improvement activity. Learners build an X-matrix linking objectives, priorities, and owners.