Lean Course

Lesson 1 • Value vs. Non-Value-Added Activities

Distinguishes value-added, necessary non-value-added, and pure waste activities. Builds analytical habits essential for process improvement.

Lesson 2 • Origins and Evolution of Lean

Traces Lean from Toyota Production System to modern applications. Provides context for why Lean principles remain relevant across industries.

Lesson 3 • Understanding the Eight Wastes

Defines and illustrates the eight categories of waste (muda). Learners practice identifying waste in real workplace scenarios.

Lesson 1 • Standard VSM Symbols and Notation

Covers the universal icon set used in VSM diagrams. Ensures learners can read and create maps consistently with industry standards.

Lesson 2 • Introduction to Value Stream Mapping

Explains the purpose and scope of value stream mapping (VSM). Connects VSM to the Lean principle of identifying the full value stream.

Lesson 3 • Designing the Future-State Map

Applies Lean principles to redesign the value stream for improved flow. Bridges analysis to actionable improvement planning.

Lesson 4 • Building the Current-State Map

Guides learners through data collection and current-state map construction. Produces a complete snapshot of how value flows today.

Lesson 1 • 5S in Office and Service Environments

Adapts 5S principles to digital files, shared spaces, and service workflows. Expands learner ability to apply 5S beyond the factory floor.

Lesson 2 • Standardize and Sustain

Develops repeatable standards and audit systems to lock in 5S gains. Addresses the most common failure point: sustaining improvements over time.

Lesson 3 • 5S Philosophy and Business Case

Explains why workplace organization is a prerequisite for Lean stability. Connects 5S discipline to quality, safety, and productivity outcomes.

Lesson 1 • Sustaining Kaizen Results

Addresses post-event follow-up, control plans, and embedding changes permanently. Prevents the common regression of improvements after the event ends.

Lesson 2 • Kaizen Philosophy and Mindset

Defines kaizen as a daily habit of small, incremental improvements. Establishes the cultural and behavioral foundations for continuous improvement.

Lesson 3 • Executing the Kaizen Event

Guides learners through the five-day kaizen event structure and facilitation techniques. Produces measurable process improvements within a compressed timeframe.

Lesson 1 • Integrating Standard Work and Visuals

Combines standard work documents with visual management for a self-regulating work environment. Prepares learners to sustain process discipline without constant supervision.

Lesson 2 • Visual Management Systems

Introduces visual controls that make process status and abnormalities immediately visible. Reduces reliance on verbal communication and memory.

Lesson 3 • Principles of Standard Work

Defines standard work as the current best method, not a rigid rule. Establishes standard work as the baseline for all future improvement.

Lesson 1 • Kanban System Design

Covers kanban types, card design, and calculation of kanban quantities. Learners design a functional kanban loop for a real process.

Lesson 2 • Optimizing One-Piece Flow

Introduces single-piece flow as the ideal state for eliminating batch-and-queue waste. Guides learners in redesigning workstations for continuous flow.

Lesson 3 • Supermarkets and FIFO Lanes

Explains controlled inventory buffers and first-in-first-out sequencing. Supports smooth flow between processes with different cycle times.

Lesson 4 • Leveling Production with Heijunka

Teaches demand leveling to smooth production schedules and reduce variability. Connects heijunka to sustainable pull system performance.

Lesson 1 • A3 Problem-Solving Report

Teaches the A3 format as a structured, visual problem-solving and communication tool. Learners complete a full A3 for a current workplace problem.

Lesson 2 • Data Collection and Basic Analysis

Introduces check sheets, Pareto charts, and run charts for evidence-based decisions. Grounds problem-solving in facts rather than assumptions.

Lesson 3 • Error-Proofing with Poka-Yoke

Applies mistake-proofing devices and methods to prevent defects at the source. Elevates solutions from detection to prevention.

Lesson 4 • Root Cause Analysis Techniques

Covers the 5 Whys and fishbone diagram for identifying true root causes. Prevents learners from implementing fixes that address only symptoms.

Lesson 1 • Lean Metrics and Performance Management

Establishes a balanced set of Lean metrics across safety, quality, delivery, and cost. Enables leaders to track transformation progress objectively.

Lesson 2 • Designing a Lean Deployment Roadmap

Guides learners in sequencing Lean initiatives across a multi-year transformation plan. Produces a practical roadmap aligned to organizational priorities.

Lesson 3 • Building a Lean Culture

Addresses the human and cultural dimensions of Lean transformation. Equips leaders to overcome resistance and build lasting engagement.

Lesson 4 • Lean Leadership Behaviors

Defines the mindset and daily practices of effective Lean leaders. Distinguishes Lean leadership from traditional command-and-control management.