This two-day training course is designed to provide a comprehensive introduction to Lean Manufacturing principles and practices. Participants will learn how to identify and eliminate waste, improve process efficiency, and enhance overall productivity. The course combines theoretical knowledge with practical exercises and case studies to ensure participants can apply Lean concepts in their workplace.

This training course is designed to be interactive and engaging, ensuring that participants leave with a solid understanding of Lean Manufacturing principles and practical skills to implement these concepts in their workplace.

OBJECTIVES

• Understand the principles and philosophy of Lean Manufacturing.

• Identify and eliminate the seven types of waste.

• Learn key Lean tools and techniques, such as Value Stream Mapping, 5S, and Kaizen.

• Develop skills to implement Lean practices in their organization.

• Understand how Lean Manufacturing can improve efficiency, quality, and customer satisfaction.

WHO SHOULD ATTEND

This course is ideal for:

• Manufacturing managers and supervisors

• Production engineers

• Quality assurance professionals

• Operations managers

• Team leaders and frontline workers

• Anyone interested in improving process efficiency and reducing waste in their organization

Additional Resources

• Online Resources: Google Classroom, links to relevant websites, videos, and online courses.

• Follow-Up Support: Google Classroom support after the course.

Day 1: Introduction to Lean Manufacturing

Morning Session

• Welcome and Introduction

  • Course overview and objectives

  • Icebreaker activity

• Introduction to Lean Manufacturing

  • History and evolution of Lean

  • The Toyota Production System (TPS)

  • Core principles of Lean: respect for people, continuous improvement, and flow

• The Seven Wastes

  • Definition and identification of the seven types of waste (Muda)

  • Practical exercise: Identifying waste in a simulated process

Afternoon Session

• Value Stream Mapping (VSM)

  • Introduction to VSM

  • Creating a current state map

  • Identifying opportunities for improvement

  • Practical exercise: Developing a current state VSM for a sample process

• Lean Tools and Techniques

  • 5S: Sort, Set in Order, Shine, Standardize, Sustain

  • Just-In-Time (JIT)

  • Kanban

  • Practical exercise: Implementing 5S in a simulated workplace

Evening Session

• Case Study Review

  • Analysis of a real-world Lean implementation case study

  • Group discussion and Q&A

• Day 1 Recap and Homework Assignment

  • Summary of key points

  • Homework: Prepare a brief analysis of a process in your workplace, identifying potential waste areas

Day 2: Implementing Lean Practices

Morning Session

• Review of Day 1 and Homework

  • Discussion of homework assignments

  • Q&A

• Kaizen Events

  • Introduction to Kaizen and continuous improvement

  • Planning and executing a Kaizen event

  • Practical exercise: Conducting a mini-Kaizen event on a simulated process

• Standard Work

  • Importance of standard work

  • Developing and documenting standard work procedures

  • Practical exercise: Creating a standard work chart for a sample process

Afternoon Session

• Lean Metrics and Performance Measurement

  • Key performance indicators (KPIs) for Lean

  • Measuring and analyzing process performance

  • Practical exercise: Calculating and interpreting Lean metrics

• Overcoming Resistance to Change

  • Strategies for implementing Lean in your organization

  • Addressing common challenges and resistance

  • Group discussion and role-playing exercises

Evening Session

• Developing a Lean Implementation Plan

  • Steps to create a Lean implementation plan

  • Identifying key stakeholders and resources

  • Practical exercise: Developing a Lean implementation plan for a process in your workplace

• Course Wrap-Up and Final Q&A

  • Summary of key learning points

  • Final Q&A session