Lean Training | Certified Lean Foundation & Practitioner Training in Heathrow

Certified Lean Foundation and Practitioner Course Outline

Module 1: About Lean

• Path to Value
• Key Lean Terms and Concepts
• Gemba Walk

Module 2: Five Steps of Lean Thinking

• Process Stapling
• Lean Temple

Module 3: Customers, Processes, and Waste

• What are Customers?
• What is a Process?
• Tension Between VOB and VOC
• What Do We Mean by Value?
• Path to Value
• Dealing with Values
• Eight Wastes of Lean

Module 4: Key Lean Metrics

• Introduction to Key Lean Metrics
• Tools and Techniques
• Spaghetti (Movement/Transportation) Diagrams
• Measles Charts
• Lean Triad
• 5S
• What is of 5S
• Steps of 5S
• What is Poka Yoke
• Two Main Types of Poka Yoke
• What is SMED?
• Employing SMED Will Enable You to…
• How SMED Looks Like?
• Voice of Customer (VOC)
• Customer Segmentation
• Four Steps of VOC Methodology and Tools
  • Identify Customers
  • Gather Customer Information
  • Analyse Customer Information
  • Determine Customer Needs
• Customer Segmentation
• SIPOC
• CSandF Web Fulfilment SIPOC
• VOC Step Two: Gather Customer Information
• VOC Step Three: Analyse Customer Information
• Affinity Diagrams
• Overview of the Kano Model
• Kano Model
• Kano Analysis: Budget TV 2012
• VOC Step Four: Determine Customer Needs
• Identifying the Requirements
• What is a Critical to Quality (CTQ)?
• Common Terminology
• Identifying the Root Cause
• Five Whys
• Root Cause Analysis (Fishbone)
• Reverse Fishbone
• Control Frameworks
• Three C’s
• Eight Ds
• Plan Do Check Act
• Introduction to Kaizen
• Kaizen
• Kaizen Philosophy
• Kaizen Events
• Formal Kaizen Roles and Process

Module 5: Managing and Building Lean Teams

• Managing Teams
• Lean Teams
• Features of Lean Teams
• High Performing Teams (HPT)
• High Performance Challenge
• Contrasting Team Structures
• Managing Progress and Demonstrating Control
• Kanban Board
• MoSCoW Prioritisation
• Daily Stand-Ups
• Managing Teams
• Work Cells
• Lean Management
• Self-Managed Team Philosophy
• Lean Manager and the Self-Managed Team
• Personality Styles
• High Performing Teams (HPT)
• Autonomous HPTs
• High Performance Challenge

Module 6: Problem-Solving

• Problem Solving
• Problem Solving Framework
• A Seven-Step Problem Solving Methodology
• Prioritisation Tools
  • Pay-off matrices
  • Weighting through voting
  • Weighting with evaluation criteria
  • Pugh Matrix

Module 7: Visual Management

• Introduction to Visual Management
• Guidelines for Visual Management

Module 8: Advanced VOC

• Advanced Intelligence Methods
• Ways of Gathering the VOC
• Intelligence Gathering: Top Tips
• Critical to Quality Trees
  • Steps to Creating a CTQ Tree

Module 9: Lean Metrics

• Metrics
• Measures and Targets
• A Reminder: Fundamental Lean Metrics
• Metrics Drive Behaviour
• Traditional Vs Lean Metrics
• Choosing the Right Metrics
• Things to Consider When Selecting Metrics
• Useful Metrics
• First and Second Project Metrics
• Metrics and Measures Roadmap

Module 10: Process Measurement

• What are Lean Process Measurements?
• Two Level Measures
• Four Sub-Metrics
• Availability
• Quality
• Performance
• Loading
• Calculating OEE and TEPP
• OEE is Not a Magic Number
• First Time Quality
• Rolled Throughput Yield (RTY)
• Work in Progress
• Completed Orders Metrics
• Delivery Metrics
• Warranty Metrics
• Customer Feedback Metrics
• Reporting Metrics
• Aims of Data Collection
• Key Performance Indicators
• Process Measurement Points
• List of Criteria for a Good Measure
• Gauge R and R
• Measurement System Resolution
• Brief Description of Data Collection Planning
• Five Steps of Data Collection Process
• Data Collection Sheet
• Frequency and Sample Size
• Evolving Your Data Collection Plan

Module 11: Total Productive Maintenance

• TPM in a Nutshell
• What is TPM?
• TPM: Goals
• Why is TPM Needed?
• Benefits of TPM
• TPM: What to Focus On?
• TPM: Where Should it be Applied?
• TPM Maturity Levels
• TPM Health Check
• Implementation Structure of TPM
• Establish Infrastructure
• Eliminate Top Issues
• Training
• Conduct Autonomous
• Conduct Planned Maintenance
• Design Maintenance Prevention

Module 12: Process Levelling (Heijunka)

• Heijunka
• Heijunka in a Nutshell
• Process Levelling Overview
• Production Levelling
• Demand Levelling
• Sequencing
• Sequencing Concepts
• Single Piece Flow
• First in First Out
• Pull
• Kanban
• Three-Bin System
• Kanban Operation Rules
• Andon
• Process Levelling
• Resource Scheduling
• Theory of Constraints
• TOC Process
• Other Techniques to Enable Level Scheduling
• Process Levelling in the Office
• What is the Minimum Cycle Time for a Form?
• Putting it All Together
• Lean Office: How it Was?
• Purchasing Department: After Laen
• The Lean Office: Putting it All Together

Module 13: Value Stream Mapping

• Value Stream Terminology
• Process Maps
• Swim Lanes
• Typical Process Map Contests
• Value Stream Maps
• Headache Tablets: Value Stream Mapping
• Process Maps
• Process Map Levels
• On the Ground Instructions (OTGIs)
• What is a Value Stream?
• Creating the “As Is” VSM
• Investigating and Understanding the Process
• Headache Tablets: Value Stream Mapping
• Creating a VSM: Process Borders Definition
• Process Boxes
• Useful VSM Metrics
• Square Wave
• Creating an Improved Process
• Steps for Building a Value Stream Map
• Action Plans
• Identifying Priorities: Effort/Impact Grid

Certified Lean Foundation and Practitioner Exam Information

The Certified Lean Foundation & Practitioner Course includes separate examinations for the Foundation and Practitioner levels. Delegates are required to pass the relevant examination to achieve each certification.

Certified Lean Foundation Exam Information

• Question Type: Multiple Choice 
• Total Questions: 50 
• Total Marks: 50 Marks 
• Pass Mark: 60%, or 30/50 Marks 
• Duration: 60 Minutes 
• Open Book/ Closed Book: Closed Book

Certified Lean Practitioner Exam Information

To achieve the Certified Lean Practitioner, candidates will need to sit for an examination. The exam format is as follows: 

• Question Type: Multiple Choice 
• Total Questions: 60 
• Total Marks: 60 Marks 
• Pass Mark: 65%, or 39/60 Marks 
• Duration: 80 Minutes
• Open Book/ Closed Book: Closed Book

Who Should Attend this Certified Lean Foundation & Practitioner Course?

This Certified Lean Foundation & Practitioner Training Course is suitable for professionals who want to develop practical knowledge of Lean principles, process improvement, and waste reduction. This course can be beneficial for the following professionals:

• Project Managers
• Lean Practitioners
• Senior Managers
• Frontline Employees
• Operational Staff
• Quality Control Professionals
• Supply Chain and Logistics Personnel

Prerequisites for the Certified Lean Foundation and Practitioner Course

There are no formal prerequisites to attend this Certified Lean Foundation & Practitioner Training Course. However, a basic understanding of Lean principles can be beneficial for the delegates.

Certified Lean Foundation and Practitioner Course Overview

Certified Lean Foundation and Practitioner Course develops a comprehensive understanding of Lean principles, customer value, process improvement, and waste reduction. It covers Lean thinking, process flow, continuous improvement, and the principles used to improve operational performance.

Delegates will develop skills in analysing processes, identifying waste, measuring performance, solving problems, and applying visual management techniques. They will also learn how tools such as Kanban, Heijunka, TPM, and process measurement support continuous improvement.

This 2-Day course by The Knowledge Academy helps delegates apply Lean methods across operational and organisational processes. They will be better equipped to strengthen process control, enhance customer value, and support sustainable continuous improvement.

Certified Lean Foundation and Practitioner Course Objectives

• To understand the fundamental principles, concepts, and terminology of Lean
• To identify waste and analyse opportunities for process improvement
• To apply Lean tools and techniques for improving process efficiency
• To use structured problem-solving methods to address process issues
• To measure process performance using relevant Lean metrics and indicators
• To support continuous improvement through Lean teams, flow, and value-focused practices

Learning Outcomes of this Certified Lean Foundation and Practitioner Course

Upon completing this Certified Lean Foundation & Practitioner Course, delegates will be able to analyse processes, identify waste, apply Lean tools, measure performance, and support structured improvement initiatives. They will also strengthen their ability to improve efficiency, customer value, and continuous improvement across organisational processes.

What’s Included in this Certified Lean Foundation and Practitioner Course?

• Certified Lean Foundation & Practitioner Examination
• World-Class Training Sessions from Experienced Instructors
• Certified Lean Foundation & Practitioner Certificate
• Digital Delegate Pack