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Lean Training

Online Instructor-led (2 days)

Online Self-paced (16 hours)

Certified Lean Foundation and Practitioner Exam

Certified Lean Foundation and Practitioner Course Outline

During this intensive two-day course, delegates will explore a range of topics that fall under the following categories:

  • Introduction to Lean
  • 5S Training
  • Visual Management
  • Mistake Proofing
  • Lean Process Mapping
  • Lean 8 Wastes Training
  • Lean Problem Solving

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Who Should Attend this Lean Training Course?

As Lean is applicable to all industries, this course is ideal for delegates originating from any business background.

Prerequisites

There are no formal prerequisites - this course is open to individuals looking to develop their knowledge of the Lean methodology.

Certified Lean Foundation and Practitioner Course Overview

The Lean Foundation and Practitioner training course are delivered over a period of two days, during which time our highly experienced and engaging trainers will provide delegates with all they need to know about Lean. The Lean technique is a pivotal tool for improving customer satisfaction by achieving quality control and removing waste. It is one of the most popular management strategies utilised globally and can be effectively applied to many industries. Thus, this certification will prove useful to any delegate, working within any sector.

By attending this training course with The Knowledge Academy, the delegate will obtain the vital tools for transforming their business. With an up-to-date understanding of the Lean methodology, they can begin to practically apply these tools to their businesses immediately after earning this impressive certification. The delegate will gain a comprehensive understanding of reviewing processes and identifying problems, finding, and eliminating waste, and improving workflow and reducing defects. 

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Certified Lean Foundation and Practitioner Exam Information

The Lean Foundation Exam is conducted at the conclusion of the first training day and consists of:

  • 40 Multiple Choice Questions
  • 60% Pass Mark
  • 50 Minutes 
  • Closed book

The Lean Practitioner Exam is conducted at the conclusion of the second day and consists of:

  • 60 Multiple Choice Questions
  • 65% Pass Mark
  • 80 Minutes 

What’s Included in this Lean Training Course?

  • The Lean Foundation and Practitioner Examinations
  • The Knowledge Academy’s Lean Foundation and Practitioner Manual
  • Experienced Instructor
  • Completion Certificate
  • Refreshments

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Certified Lean Foundation Exam

The Lean Foundation Exam is conducted at the conclusion of the first training day and consists of:

  • Multiple choice questions
  • Duration of 60 minutes
  • 60% pass mark
  • Closed book
  • Supervised

Certified Lean Practitioner Exam

The Lean Practitioner Exam consists of:

  • Multiple choice questions
  • Duration of 80 minutes
  • 65% pass mark
  • Closed book
  • Supervised

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Online Instructor-led (1 days)

Online Self-paced (8 hours)

Certified Lean Foundation Exam

Lean Foundation Course Outline

The Lean Foundation one-day training course is specifically designed to provide delegates with an understanding of the basics of Lean and its use within the business environment. During the course, delegates will explore three modules:

  • Introduction to Lean
  • 5S Training
  • Visual Management

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Who Should Attend this Lean Training Course?

As Lean is applicable to all industries, this course is ideal for delegates originating from any business background.

Prerequisites

There are no formal prerequisites - this course is open to individuals looking to develop their knowledge of the Lean methodology.

Certified Lean Foundation​ Course Overview

This Lean Foundation course will provide delegates with a foundational knowledge of the Lean methodology, a popular management strategy utilised by businesses worldwide. The Lean technique is a pivotal tool for improving customer satisfaction by achieving quality control and removing existent waste.

A vast number of organisations are continuously looking to improve the efficiency of their business processes and enhance quality control. Introducing Lean Thinking to a business can result in multiple benefits, including greater customer satisfaction and business growth. This course, taught by our experienced instructors, will supply each delegate with all they need to know about Lean fundamentals. Consequently, this course succeeds in expanding the delegate’s understanding of how to improve business processes through the elimination of waste and reduction of defects.

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What's Included in this Lean Training Course?

  • The Lean Foundation Examination
  • The Knowledge Academy’s Lean Foundation Manual
  • Experienced Instructor
  • Completion Certificate
  • Refreshment

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Certified Lean Foundation Exam

The Lean Foundation Exam is conducted at the conclusion of the first training day and consists of:

  • Multiple choice questions
  • Duration of 60 minutes
  • 60% pass mark
  • Closed book

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Online Instructor-led (1 days)

Online Self-paced (8 hours)

Certified Lean Practitioner Exam

Certified Lean Practitioner Course Outline

The Lean Practitioner one-day training course has been expertly designed to provide delegates with an understanding of Lean and how to practically apply its methodology to any type of business. During the course, delegates will explore four detailed modules:

Module 1: Managing and Building Lean Teams

  • Managing Teams
  • Role of the Team Leader
  • Work Cells
  • Lean Management
  • Self-Managed Team Philosophy
  • Lean Manager and the Self-Managed Team
  • Personality Styles
  • High Performing Teams (HPT)
  • High Performance Challenge

Module 2: Visual Management

  • Introduction to Visual Management
  • Guidelines for Visual Management
  • Cell Information Boards

Module 3: Advanced VOC

  • Advanced Intelligence Methods
  • Ways of Gathering the VOC
  • Intelligence Gathering: Top Tips
  • Critical to Quality Trees
  • CTQ Trees in Action

Module 4: Lean Metrics

  • 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
  • Key Metrics

Module 4: Process Measurement

  • What are Lean Process Measurements?
  • Two Top Level Measures
  • Four Sub-Metrics
  • Calculating OEE and TEPP
  • 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
  • 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
  • Evolving Your Data Collection Plan

Module 5: TPM (Total Productive Maintenance)

  • TPM in a Nutshell
  • TPM: Goals
  • TPM: What to Focus On        
  • TPM Maturity Levels
  • TPM Health Check (Capability Assessment)
  • Implementation Structure of TPM
  • Establish Infrastructure
  • Eliminate Top Issues
  • Conduct Autonomous Maintenance
  • Conduct Planned Maintenance
  • Design Maintenance Prevention

Module 6: Process Levelling

  • Process Levelling (Theory)
  • Process Levelling: Demand Management
  • Resource Scheduling: Simon’s Coffee Bar
  • Theory of Constraints
  • Process Levelling in the Office
  • What is the Minimum Cycle Time for a Form?

Module 7: Value Stream Mapping

  • Process Maps
  • Swim Lanes
  • Process Map Levels
  • Value Stream Maps
  • Creating ‘As In’ VSM
  • Investigating and Understanding the Process
  • Creating a VSM: Process Borders Definition
  • Square Wave
  • Creating an Improved Process
  • Steps for Building a Value Stream Map

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Who Should Attend this Lean Training Course?

  • Managers and Team Leaders who will be charged with making improvements to areas of the business under their control
  • Senior Managers who wish to oversee the implementation of Lean Thinking in their business area

Prerequisites

Candidates are required to have the following prior to attending this course:

  • An excellent understanding of Lean, Lean thinking and the basic Lean tools (can be acquired on Introduction to Lean course)
  • Completion of Introduction to Lean or Lean Six Sigma Yellow Belt is recommended

Certified Lean Practitioner​ Course Overview

Lean is a set of management methods used to enhance productivity and efficiency by removing waste from the process. The essence of Lean is focused on diminishing and eliminating non-valuable actions and waste. It is one of the most popular management strategies utilised globally and can be effectively applied to many industries. The Lean technique plays a vital role in improving customer satisfaction by achieving quality control. Many professionals and organisations use it for enhancing their operational processes. Thus, understanding Lean and practically applying Lean practices could benefit businesses of any size or type. Attending this Certified Lean Training will enable individuals to gain skills required to implement Lean that will help them get more advanced job opportunities.

This 1-day Lean Practitioner course is designed to explore a wide range of Lean topics. This course will ensure that the delegates get a well-rounded, in-depth understanding of Lean and its advantages to the business. They will learn how to review processes, identify problems, find and eliminate waste, and improve workflow. Delegates will also learn concepts like lean metrics, metrics that drive behaviour, useful metrics, lean process measurements, measurement system resolution, and many other concepts that will support business performance. Our highly skilled and experienced trainer will conduct this course with newly devised engaging and interactive methods to develop delegates’ knowledge of using Lean practices.

Other than the above concepts, delegates will also learn the following topics:

  • High-performance challenge
  • Traditional vs Lean metrics
  • Rolled Throughput Yield (RTY)
  • Five steps of the data collection process
  • Total Productive Maintenance (TPM)

At the end of this training course, delegates will be able to use the Lean metrics for greater control of the processes for continuous quality. They will become well-versed in perceiving key performance indicators and rise as leaders in their respective fields and be able to transform their teams using Lean practices.

If delegates want to acquire more business improvement skills, then they can choose courses like Lean Awareness TrainingLean Processes and Tools TrainingEnterprise Integration FundamentalsEnterprise Integration Advanced training, and many more from our Lean Training section.

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What's Included in this Lean Training Course?

  • The Lean Practitioner Examination
  • The Knowledge Academy’s Lean Practitioner Manual
  • Experienced Instructor
  • Completion Certificate
  • Refreshments

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Certified Lean Practitioner Exam

The Lean Practitioner Exam consists of:

  • Multiple choice questions
  • Duration of 80 minutes
  • 65% pass mark
  • Closed book
  • Supervised

Show moredown

Online Instructor-led (1 days)

Online Self-paced (8 hours)

Introduction to Lean Course Outline

Module 1: What is Lean?

  • Lean in a Nutshell
  • The Lean Temple
  • What is Lean?
  • Fables and Facts
  • What Lean should look like
  • What is changing at service companies?
  • Origins of Lean
  • Customers, Processes, and Waste
  • The Path to Value
  • Seven Wastes: A Healthcare Example
  • The Lean Principles and the 3Cs
  • Key Lean Metrics

Module 2: One Sentence Expert – A Description of the Key Parts of Lean

  • Gemba
  • Hoshin Kanri (Policy Deployment)
  • Jidoka (Autonomation)
  • Just in Time (JIT)
  • Six Big Losses
  • 5S and the Steps of 5S
  • Poka Yoke
  • Single Minute Exchange of Dies (SMED)
  • Total Productive Maintenance (TPM)
  • Standardised Work and On the Ground Instructions (OTGIs)
  • Visual Factory and Value Stream Mapping

Module 3: The Case for Lean

  • The Cost of Poor Quality
  • The Iceberg Theory
  • Identifying Hidden Costs
  • Setting up Lean Thinking and the Costs of Adoption
  • Prerequisites and Essential Requirements
  • Timeframes

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Who should attend this Lean Training Course?

Professionals who are suited to this course are:

  • Managers and Senior Managers of organisations considering adopting Lean methodology
  • Production Staff who are considering training in Lean Thinking and require a concise introduction
  • Staff working in a Lean environment who are new to the subject and want to learn more

Prerequisites

There are no pre-requisites required prior to attending this course. 

Introduction to Lean Overview

Increasing numbers of businesses are using Lean Thinking to provide a competitive advantage in today’s increasingly fierce market. This course will provide thinkers and leaders with a solid introduction to what Lean is about and why it will benefit an organisation to embrace it.

Lean provides opportunities for companies to reduce waste and save money, while improving customer satisfaction. The tools and techniques have been used by all the major companies in the world to provide massive savings and improved customer satisfaction.

What is Lean?

The Lean methodology is all about maximising customer value whilst minimising waste. This technique is all about creating more value for clients by using fewer resources. The main objective for the Lean methodology is to deliver the best value for the customer by creating the perfect process that eliminates all waste.

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What’s Included in this Lean Training Course?

  • The Knowledge Academy’s Introduction to Lean Manual
  • Experienced Instructor
  • Completion Certificate
  • Refreshments

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Online Instructor-led (1 days)

Online Self-paced (8 hours)

Value Stream Mapping Course Outline

This Value Stream Mapping course focuses on creating value for the customer and eliminating waste. A value stream is the activity within an organisation that creates value to the customer. Value Stream Mapping is a tool which shows individuals how to understand, analyse, and improve a value stream. 

  • Introduction
  • Customer value
  • Value adding & non-value adding activities
  • What is a Value Stream Mapping?
  • Developing a Current State Map
  • Identifying waste & flow
  • Developing a Future State Map
  • Creating continuous flow
  • Level Scheduling
  • Developing an improvement plan

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Who should attend this Value Stream Mapping Course?

Value Stream Mapping is recommended for individuals in the service and manufacturing industries who have a basic awareness of lean tools and techniques.

Prerequisites

There are no prerequisites for this course.

Value Stream Mapping Course Overview

The Lean methodology is all about maximising customer value whilst minimising waste. This technique is all about creating more value for clients by using fewer resources. The main objective for the Lean methodology is to deliver the best value for the customer by creating the perfect process that eliminates all waste.

This Value Stream Mapping course focuses on creating value for the customer and eliminating waste. A value stream is the activity within an organisation that creates value to the customer. Value Stream Mapping is a tool which shows individuals how to understand, analyse, and improve a value stream. Lean Thinking has a significant impact within an organisation by simplifying processes and improving performance.

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What’s Included in this Value Stream Mapping​ Course?

  • The Knowledge Academy’s Value Stream Mapping Manual
  • Experienced Instructor
  • Completion Certificate
  • Refreshments

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Online Instructor-led (1 days)

Online Self-paced (8 hours)

5S Training​ Course Outline

Introduction to 5S

  • Lean Manufacturing
  • Eight Wastes – Healthcare Example
  • Tips for 5S
  • Poka Yoke
  • What is SMED?
  • Benefits of 5S

Getting Started with 1S Sort

  • Red Tagging
  • Removing Unnecessary Items

Introduction to 2S Set

  • Determining Equipment Requirements
  • Equipment Layout
  • Storage Methods
  • Visual Management

3S Shine

  • General Cleaning
  • Inspection and Preventive Maintenance

4S Standardise

  • Activity Planning and Resourcing
  • Developing Procedures
  • Training

5S Sustain

  • Auditing
  • Maintaining and Improving Standards
  • Implementation Plan Development

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Prerequisites

There are no prerequisites to attend this course.

Audience

Anyone who wishes to learn about how 5S works and how it should be implemented can attend this course.

5S Training​ Course Overview

5S is an organisational method describing how to organise a workspace. It is one of the most widely adopted techniques from the lean manufacturing toolbox. The main objective of 5S is to create a clean, orderly environment where there is a place for everything, and everything is in its place. 5S makes it easier for people to do this without wasting time.

This 5S Training is designed to provide knowledge on different elements of 5S. Topics covered include the numerous benefits of 5S, how to remove unnecessary items, equipment layout, storage methods, visual management, general cleaning, activity planning and resourcing. Delegates will also become familiarised with the concepts of red-tagging and auditing. By the end of this training, delegates will be able to maintain and improve standards and implement plan development.

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  • Delegate pack consisting of course notes and exercises
  • Manual
  • Experienced Instructor

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Online Instructor-led (1 days)

Online Self-paced (8 hours)

Lean Awareness Training Course Outline

  • Introduction
  • Quality Improvement PDCA and DMAIC Models
  • 5 Lean Principles - Lean Thinking Game
  • 7 Deadly Wastes
  • Customer Value, Value Add, Value Enabling and Non-Value Add
  • Value Streams and Value Stream Mapping
  • Essential Lean Tools and Techniques
  • 5S and the Numbers Game
  • Getting Started
  • Lean Leadership and Culture

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Prerequisites

There are no prerequisites for attending this course.

Audience

This course is intended for anyone involved with the Lean initiative from both the manufacturing and service sectors.

Lean Awareness Training​ Course Overview

The Lean methodology is a powerful and dynamic process improvement methodology that brings a host of valuable tools to the workplace. It helps to reduce waste and increase the efficiency of an organisation. Deployed effectively with leadership support and the right training on the right tools, Lean can reduce costs, as well as improve productivity and quality.

In this 1-day Lean Awareness training course, delegates will gain an in-depth knowledge of Lean, its principles, models, tools, and techniques, and how to approach implementation. This Lean Awareness training will provide delegates with a solid understanding of topics such as 5 lean principles - lean thinking game, quality improvement PDCA and DMAIC models, essential lean tools, and techniques, 5S and the numbers game, customer value, value add, value enabling and non-value add, 7 deadly wastes, and much more.

After attending this course, delegates will be able to understand the benefits of Lean for their organisation. They will realise how Lean’s tools and techniques can help them to reduce waste in the workplace for more productivity.

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  • Delegate pack consisting of course notes and exercises
  • Manual
  • Experienced Instructor

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Online Instructor-led (1 days)

Online Self-paced (8 hours)

Lean Processes and Tools Training​ Course Outline

Customer Focus

  • SIPOC, Kano, CTQ
  • QCD Lean Metrics

History and Features of Lean and Six Sigma

Principles of Lean Thinking

  • Batch Size, Inventory and Flow
  • Seven Wastes
  • 5S (Workplace Organisation)
  • Lean Methods and Tools

Theory of Constraints

  • Herbie

Process Thinking

The Value Stream

  • Kaizen
  • Current State and Future State

Process Mapping

  • Flowchart, Spaghetti Map
  • Time Value Map

Layout, Cells and Lines

The Challenge of Change

  • The Change Cycle

DMAIC Process

Kaizen Blitz

Root Cause Analysis

More on Lean

  • Standard Work
  • SMED, Poka-Yoke
  • Total Productive Maintenance TPM
  • Visual Workplace
  • Kanban

Implementation

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Prerequisites

Before attending this course, delegates should have completed Lean Awareness training.

Audience

This course is intended for:

  • Production and Maintenance Managers/Executives
  • Quality Management
  • Consultants

Lean Processes and Tools Training​ Course Overview

Lean thinking is based on the legendary Toyota Production System that produces very high-quality products in a brief time and at low cost. Lean delivers methods and tools that help organisations to make major improvements in lead time, cost reduction and product or service quality.

This 1-day Lean Process and Tools training course will provide delegates with theory and practical exercises of Lean to identify and undertake improvement activities. Delegates will gain comprehensive knowledge of processes and useful tools of Lean. In this course, delegates will learn topics such as SIPOC, Kano, CTQ, Principles of lean thinking, Process mapping, Layout, cells and lines, Root cause analysis and Kanban.

After attending this course, delegates will be able to understand key elements of Lean thinking and methodology, customer value, the process of identifying and eliminating the waste, and more.

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  • Delegate pack consisting of course notes and exercises
  • Manual
  • Experienced Instructor

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Not sure which course to choose?

Speak to a training expert for advice if you are unsure of what course is right for you. Give us a call on +44 1344 203999 or Enquire.

What our customers are saying

Frequently asked questions

FAQ's

There are no prerequisites for enrolling on our Introduction to Lean certification. Yet, to undertake our Value Stream Mapping course, delegates must have a basic awareness of Lean tools and techniques. In addition, to undertake the Lean Practitioner course, candidates must have an excellent knowledge of Lean and it is recommended that the Lean Six Sigma Yellow Belt certification be completed prior to beginning this course.
We will provide you with: The Knowledge Academy Courseware Book, an experienced instructor, refreshments.
Our Introduction to Lean and Value Stream Mapping courses do not include exams. However, the Lean Practitioner does have an exam at the end of the last day of the course.
Yes, The Knowledge Academy provides support for all of its delegates, either via phone or email, both during the course and after completion.
Please see our Lean Training courses available in Philippines
The Knowledge Academy is the Leading global training provider in the world for Lean Training.
The price for Lean Training certification in Philippines starts from $.

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