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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

Module 1: About Lean

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

Module 2: Five Steps pf 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 and 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
  • What is of 5S and Steps of 5S
  • Introduction to Poka Yoke and Types
  • What is SMED?
  • 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
  • Overview of the Kano Model
  • What is a Critical to Quality (CTQ)?
  • Common Terminology
  • Identifying the Root Cause
  • Five Whys
  • Root Cause Analysis (Fishbone)
  • Reverse Fishbone
  • Control Frameworks
  • Overview
  • Three C’s
  • Eight Ds
  • Plan Do Check Act
  • Introduction to 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
  • Work Cells
  • Self-Managed Team Philosophy
  • Lean Manager and the Self-Managed Team
  • Personality Styles
  • Autonomous HPTs

Module 6: Problem-Solving

  • Problem Solving
  • Problem Solving Framework
  • A Seven-Step Problem Solving Methodology
  • Prioritisation Tools

Module 7: Visual Management

  • Introduction to Visual Management
  • Guidelines for Visual Management
  • Advanced Intelligence Methods
  • Ways of Gathering the VOC
  • Intelligence Gathering: Top Tips
  • Critical to Quality Trees

Module 8: Advanced VOC

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

Module 9: Lean Metrics

  • Metrics
  • Measures and Targets
  • 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
  • Calculating OEE and TEPP
  • OEE is Not a Magic Number
  • First Time Quality
  • 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 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 and 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?

Module 13: Value Stream Mapping

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

 

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 Who should attend this Certified Lean Foundation & Practitioner Course?

This Certified Lean Foundation & Practitioner Course is designed to provide delegates with a comprehensive understanding of Lean principles and methodologies. The Certified Lean Foundation & Practitioner 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 of the Certified Lean Foundation & Practitioner Course

There are no formal prerequisites for this course. However, a basic understanding of Lean principles can be beneficial.

 

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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What’s included in this Certified Lean Foundation & Practitioner Course?

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

Show moredown

Certified Lean Foundation Exam Information

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

  • 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

Show moredown

Online Instructor-led (1 days)

Online Self-paced (8 hours)

Certified Lean Foundation Exam

Lean Foundation Course Outline

Module 1: About Lean

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

Module 2: Five Steps pf 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 and 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
  • What is of 5S and Steps of 5S
  • Introduction to Poka Yoke and Types
  • What is SMED?
  • 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
  • Overview of the Kano Model
  • What is a Critical to Quality (CTQ)?
  • Common Terminology
  • Identifying the Root Cause
  • Five Whys
  • Root Cause Analysis (Fishbone)
  • Reverse Fishbone
  • Control Frameworks
  • Overview
  • Three C’s
  • Eight Ds
  • Plan Do Check Act
  • Introduction to Kaizen
  • Kaizen Philosophy
  • Kaizen Events
  • Formal Kaizen Roles and Process

 

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Who should attend this Certified Lean Foundation Course?

The Certified Lean Foundation Course is designed to understand the fundamentals of Lean methodologies and basics of Lean for business improvement. This course will be beneficial for the following professionals:

  • Production Managers
  • Operations Managers
  • Quality Managers
  • Lean Practitioners
  • Industrial Engineers
  • Supply Chain Managers
  • Customer Service Representatives

Prerequisites of the Certified Lean Foundation Course

There are no formal prerequisites to attend the Certified Lean Foundation Course. However, a basic understanding of Lean concepts would be beneficial.

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 Certified Lean Foundation Course?

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

Show moredown

Certified Lean Foundation Exam Information

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

  • 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

Show moredown

Online Instructor-led (1 days)

Online Self-paced (8 hours)

Certified Lean Practitioner Exam

Certified Lean Practitioner Course Outline

Module 1: 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
  • Work Cells
  • Self-Managed Team Philosophy
  • Lean Manager and the Self-Managed Team
  • Personality Styles
  • Autonomous HPTs

Module 2: Problem-Solving

  • Problem Solving
  • Problem Solving Framework
  • A Seven-Step Problem Solving Methodology
  • Prioritisation Tools

Module 3: Visual Management

  • Introduction to Visual Management
  • Guidelines for Visual Management
  • Advanced Intelligence Methods
  • Ways of Gathering the VOC
  • Intelligence Gathering: Top Tips
  • Critical to Quality Trees

Module 4: Advanced VOC

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

Module 5: Lean Metrics

  • Metrics
  • Measures and Targets
  • 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 6: Process Measurement

  • What are Lean Process Measurements?
  • Two Level Measures
  • Four Sub-Metrics
  • Calculating OEE and TEPP
  • OEE is Not a Magic Number
  • First Time Quality
  • 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 Data Collection Plan

Module 7: 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 8: 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 and 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?

Module 9: Value Stream Mapping

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

 

Show moredown

Who should attend this Certified Lean Practitioner Course?

The Certified Lean Practitioner Course is designed for professionals who are looking to improve their business with Lean thinking. This course will be more beneficial for the following professionals:

  • Manufacturing Engineers
  • Operations Managers
  • Quality Control Professionals
  • Customer Service Representatives
  • IT Professionals
  • Supply Chain and Logistics Personnel
  • Managers and Department Heads

Prerequisites of the Certified Lean Practitioner Course

The Certified Lean Practitioner Course demands a proper understanding of the basic Lean tools and Lean thinking. It is also recommended to complete the Introduction to Lean or Lean Six Sigma Yellow Belt Course before taking up this Certified Lean Practitioner Course.

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.

Show moredown

What’s included in this Certified Lean Practitioner Course?

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

Show moredown

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

Show moredown

Online Instructor-led (1 days)

Online Self-paced (8 hours)

Introduction to Lean Course Outline

Module 1: What is Lean?

  • Introduction to Lean
  • Lean in a Nutshell
  • Lean Temple
  • Fables and Facts
  • What Lean Should Look Like?
  • Lean Thinking can Transform Business
  • Lean is Not Just for Manufacturing
  • What is Changing at Service Companies?
  • Origins of Lean
  • Customers, Processes, and Waste
  • What are Customers?
  • Anatomy of a Process
  • Who Wants the Outputs?
  • Tension Between the VOB and VOC
  • Meaning of Value
  • Path to Value
  • Dealing with Values
  • Seven Wastes (Muda) of Lean
  • Introducing Lean Methodologies
  • Lean Principles
  • 3Cs
  • Key Lean Metrics

 Module 2: One Sentence Expert

  • Gemba (The Real Place)
  • Gemba Tools
  • Kaizen
  • Hoshin Kanri (Policy Deployment)
  • Jidoka (Autonomation)
  • Just in Time (JIT)
  • Six Big Losses
  • 5S and the Steps of 5S
  • What is Poka Yoke?
  • Single Minute Exchange of Dies (SMED)
  • Total Productive Maintenance (TPM)
  • Standardised Work
  • On the Ground Instructions (OTGIs)
  • Visual Factory
  • Value Stream Mapping
  • Headache Tablets: Value Stream Mapping (“As Is Example)

Module 3: Case for Lean

  • Cost of Poor Quality
  • Iceberg Theory
  • Identifying Hidden Costs
  • Benefits of a Simple Lean Project
  • Categories Associated with the Cost of Poor Quality
  • In Practice it’s a Balancing Act
  • Setting up Lean Thinking in Business
  • Costs of Adoption
  • Prerequisites and Essential Requirements
  • Timeframes

 

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Who should attend this Introduction to Lean Course?

The Introduction to Lean Course is a beginner-level course which is designed to help professionals adopt Lean methodologies and Lean Thinking. This course will be more beneficial for the following professionals:

  • Managers and Supervisors
  • Process Improvement Specialists
  • Operations Managers
  • Quality Control Personnel
  • Supply Chain Professionals
  • Project Managers
  • Continuous Improvement Enthusiasts

Prerequisites of the Introduction to Lean Course

There are no prerequisites to attend the Introduction to Lean 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 Introduction to Lean Course?

  • World-Class Training Sessions from Experienced Instructors 
  • Introduction to Lean Certificate
  • Digital Delegate Pack 

Show moredown

Online Instructor-led (1 days)

Online Self-paced (8 hours)

Value Stream Mapping Course Outline

Module 1: Overview of Value Stream Mapping

  • Overview: Value Stream Maps (VSMs)
  • What is a Value Stream?
  • Process Maps
  • Swim Lanes
  • Process Map Levels
  • Levels of Process Maps

Module 2: Customer Value

  • What is a SIPOC?
  • Benefits of SIPOC
  • SIPOC Layout
  • CS&F Web Fulfilment SIPOC

Module 3: What is Value Stream Mapping?

  • Value Stream Maps (VSMs)
  • Practical VSMs
  • Deploying VSMs
  • Types of VSM
  • Comparing Process Types
  • Manufacturing VSM
  • Creating the ‘AS-IS’ VSM
  • Investigating and Understanding the Process
  • Headache Tablets: Value Stream Mapping (‘As Is’)
  • Creating a VSM: Process Borders Definition
  • Using Swim Lane Diagrams to Identify Logical Process Blocks
  • Process Boxes
  • Capturing Data
  • Useful VSM Metrics
  • First-Time Yield (FTY)
  • Rolled Throughput Yield (RTY)
  • VSM Metrics
  • Square Wave
  • Kaizen Burst
  • Creating an Improved Process
  • Transactional VSM: Mortgage Application (As-Is)
  • Layout Diagrams
  • On the Ground Instructions (OTGIs)

Module 4: Interactive Value Stream Map

  • Interactive
  • Format of the Interactive VSM
  • Common Rows on the Interactive VSM
  • How to Create an Interactive Map?
  • Interactive Map and VSM
  • Interactive VSM Symbols and Measures
  • Service Transaction Box

Module 5: Overview of Data Collection

  • Data Collection Planning

Module 6: Data Collection Process

  • Building the Hierarchies
  • Breakdown Structure
  • Spider Diagram
  • Planning Ideas
  • Measures and Modelling Tools
  • Data Collection
  • Breakdown Structure
  • Spider Diagram
  • Process Measurement Points
  • Measurement System Analysis (MSA)
  • Analysing the Data
  • Frequency and Sample Size

Module 7: Data Collection Planning and Documentation

  • Data Collection
  • Evolving Data Collection Plan

 

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Who should attend this Value Stream Mapping Course?

The Value Stream Mapping Course is for individuals from the manufacturing and service industries. This course will be more beneficial for the following professionals:

  • Process Improvement Specialists
  • Manufacturing Engineers
  • Operations Managers
  • Continuous Improvement Professionals
  • Quality Assurance Experts
  • Project Managers
  • Customer Service Representatives

Prerequisites of the Value Stream Mapping Course

There are no formal prerequisites for the Value Stream Mapping Course. However, having a basic understanding of Lean tools and Lean techniques can be beneficial. 

Value Stream Mapping Course Overview

Value Stream Mapping is a lean manufacturing technique used to evaluate, plan, and control the information and material flow needed to deliver a product to a customer. It is enormously beneficial for organisations to improve business outcomes through lean production processes. This training helps learners be better able to recognise areas for improvement, pinpoint them, and then develop a practical plan for optimisation. Holding the required understanding of using the value stream mapping tool for better process and business development can open up various new and improved job roles and opportunities with an enhanced pay scale.

This 1-day Value Stream Mapping Training course focuses on teaching delegates how to create value for customers while eliminating waste. During this training, delegates will be able to monitor progress and make adjustments as needed to ensure that the improvements are sustained over time. They will also learn about how to develop an implementation plan to achieve the future state map. Our highly skilled and professional trainers with years of teaching experience will deliver this training and try their best to make delegates understand things easily.

Course Objectives

  • To learn how to identify and analyse waste and inefficiencies in a process
  • To sustain improvements over time through ongoing monitoring and adjustment
  • To understand the importance of visual management in Lean and VSM
  • To identify and prioritise improvement opportunities based on impact and feasibility
  • To create a future state map that eliminates waste and increases efficiency
  • To develop an implementation plan to achieve the future state map

After attending this training course, delegates will be able to implement a standard process to collect data in order to avoid wasteful mistakes. They will also be able to improve workflow and reduce defects to get more productive outcomes.

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What’s included in this Value Stream Mapping Course?

  • World-Class Training Sessions from Experienced Instructors  
  • Value Stream Mapping Certificate
  • Digital Delegate Pack 

Show moredown

Online Instructor-led (1 days)

Online Self-paced (8 hours)

5S Training​ Course Outline

Module 1: Introduction to 5S

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

Module 2: Getting Started with 1S Sort

  • 1S Sort
  • Red Tagging
  • Removing Unnecessary Items

Module 3: Introduction to 2S Set

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

Module 4: 3S Shine

  • General Cleaning
  • Inspection and Preventive Maintenance

Module 5: 4S Standardisation

  • Activity Planning and Resourcing
  • Developing Procedures
  • Training

Module 6: 5S Sustain

  • Auditing
  • Maintaining and Improving Standards
  • Implementation Plan Development

 

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Who should attend this 5S Training Course?

The 5S Training Course is designed for individuals and teams who are looking forward to learning and implementing the principles of 5S methodology - (sort, set in order, shine, standardise, sustain) for workplace organisation and efficiency. This course will be more beneficial for the following professionals:

  • Frontline Employees
  • Lean Practitioners
  • Supervisors
  • Managers
  • Process Improvement Specialists
  • Quality Control Personnel
  • Operations Staff

Prerequisites of the 5S Training Course

There are no formal prerequisites to attend this 5S Training 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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 What’s included in this 5S Training Course?

  • World-Class Training Sessions from Experienced Instructors   
  • 5S Training Certificate
  • Digital Delegate Pack 

Show moredown

Online Instructor-led (1 days)

Online Self-paced (8 hours)

Lean Awareness Training Course Outline

Module 1: Introduction to Lean

  • About Lean
  • Focus of Lean
  • Origins of Lean
  • Lean in a Nutshell
  • Lean Temple

Module 2: Quality Improvement – PDCA and DMAIC

  • Plan Do Check Act
  • DMAIC Cycle
  • What is DMAIC?

Module 3: Lean Principles

  • 5 Lean Principles

Module 4: Seven Wastes

  • Muda (Waste)
  • Seven Wastes (Muda) of Lean
  • Types of Demand
  • Failure Demand
  • 7 Wastes

Module 5: Value

  • What are Customers?
  • Who Wants the Outputs?
  • Tension Between the VOB and VOC
  • What is Mean by Value?
  • Path to Value
  • Dealing with Values

Module 6: Value Streams and Value Stream Mapping

  • Value Stream Terminology
  • Process Maps
  • Swim Lanes
  • Process Mapping
  • Typical Process Map Contents and Symbols
  • Value Stream Maps
  • What is a "Value Stream"?
  • Value Stream Mapping
  • Process Boxes
  • Value Stream Symbols

Module 7: Key Lean Tools and Techniques

  • Tools and Techniques
  • What is Poka-Yoke?
  • Two Main Types of Poka Yoke
  • Advantages of Poka Yoke
  • Three Poka-Yoke Methods
  • What is SMED?
  • Why do We Need to Listen to the VOC?
  • Determine the Value and Define the Voice of the Customer (VOC)
  • VOC Methodology
  • Heijunka in a Nutshell
  • Description of Pull Systems
  • Push Vs Pull Systems
  • What are Kanbans?
  • Three-Bin System
  • Root Cause Analysis
  • 5 Whys and How to Complete the 5 Whys?
  • Problem Solving Framework
  • 7 Steps of Problem Solving
  • Prioritisation Tools
  • Kaizen, Kaizen Philosophy, and Kaizen Events
  • Formal Kaizen Roles and Process
  • Features of Lean Teams
  • High Performing Teams (HPT)
  • Contrasting Team Structures
  • Managing Progress and Demonstrating Control

Module 8: Getting Started

  • Key Lean Terms and Concepts

Module 9: 5S and the Numbers Game

  • What is 5S?
  • Steps of 5S
  • Numbers Game

Module 10: Leadership and Culture

  • Managing Teams
  • Role of the Team Leader
  • Lean Management
  • Self-Managed Team Philosophy
  • Lean Manager and the Self-Managed Team
  • Leadership and Culture

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Who should attend this Lean Awareness Training Course?

The Lean Awareness Training Course is designed for individuals across various roles and functions who want to gain a foundational understanding of Lean principles and concepts. This course will be more beneficial for the following professionals:

  • Quality Control Personnel
  • Operations and Production Staff
  • Frontline Employees
  • Supervisors and Managers
  • Administrative Staff
  • Continuous Improvement Enthusiasts
  • Supply Chain and Logistics Personnel

Prerequisites of the Lean Awareness Training Course

There are no formal prerequisites to attend the Lean Awareness Training Course.

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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What’s included in this Lean Awareness Training Course?

  • World-Class Training Sessions from Experienced Instructors     
  • Lean Awareness Training Certificate
  • Digital Delegate Pack 

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Online Instructor-led (1 days)

Online Self-paced (8 hours)

Lean Processes and Tools Training​ Course Outline

Module 1: Lean Processes 

  • What is Lean? 
  • What is Value? 
  • What is Waste? 
  • Constraints of Performance Improvement 
  • Principles of Lean 
  • Four Goals of Lean 
  • Seven Forms of Waste 
  • Lean Tools 
  • Poka-Yoke 
  • 5s Visual Workplace 
  • Time Management 
  • Continuous Improvement 
  • Work in Process 
  • Material Management 
  • Value Stream Mapping 
  • Value Added Vs Non-Value Added 
  • Creating Lean Systems 

Module 2: Standardised Work 

  • Why Standardised Work? 
  • Elements of Standardised Work 
  • Disconnects and Misconceptions 

Module 3: Reducing Batch Size 

  • Introduction to Reducing Batch Size 

Module 4: Poka-Yoke 

  • What is Poka-Yoke? 
  • Development of Poka-Yoke 
  • Quality Control Vs Poka-Yoke 
  • Purpose of Poka-Yoke 

Module 5: Total Productive Maintenance 

  • Introduction to Total Productive Maintenance 
  • 5S Foundation 

Module 6: Time Management 

  • Time Management 
  • Benefits of a JIT system 
  • Requirements for Implementing Just in Time 

Module 7: Value Stream Mapping 

  • Guiding Lean Principles 
  • Lean Agile Pyramid 
  • Lean Agile Value Stream 
  • Waste Elimination Using Agile 

Module 8: Forming Pull Systems 

  • Push Vs Pull in Scrum 
  • Favour the Pull Model 

Module 9: Lean Six Sigma 

  • Improvement 
  • Lean Six Sigma  
    • Improvement 
    • Timeline 
    • Process 
  • What is Waste in Lean? 
  • Lean Vs Six Sigma 
  • What Lean Six Sigma Wants to Achieve? 
  • What Makes a Good Lean Six Sigma Project? 
  • DMAIC Methodology 
    • Define
    • Measure 
    • Analyse 
    • Improve Control 

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Who should attend this Lean Processes and Tools Training?

The Lean Processes and Tools Course is designed for professionals who are looking to strengthen their understanding of Lean methodologies and acquire practical skills in using Lean tools for process improvement. This training can be beneficial for the following professionals:

  • Process Improvement Specialists
  • Lean Practitioners
  • Operations Managers
  • Quality Control Personnel
  • Continuous Improvement Teams
  • Project Managers
  • Industrial Engineers

Prerequisites for the Lean Processes and Tools Training

There are no formal prerequisites for this course. However, a basic understanding of Lean and completing the Lean Awareness Training can be beneficial for the learners.  

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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What’s included in this Lean Processes and Tools Training?

  • World-Class Training Sessions from Experienced Instructors      
  • Lean Processes and Tools Training Certificate
  • Digital Delegate Pack 

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Online Instructor-led (1 days)

Online Self-paced (8 hours)

Advanced Lean Techniques and Understanding Customers Training Course Overview

Module 1: Introduction to Lean Thinking

  • What is Lean Thinking?
  • Why is Lean Thinking Important?
  • Lean Thinking Principles
  • Benefits of Lean Thinking
  • Key Components of Lean Thinking

Module 2: Advanced Lean Techniques for Process Improvement

  • Overview of Process Improvement Techniques
  • Value Stream Mapping
  • Kaizen Events
  • Lean Six Sigma Methodologies   

Module 3: Advanced Lean Techniques for Product Development

  • Overview of Lean Product Development
  • Agile Methodologies
  • Lean Start-Up Principles
  • Design Thinking Techniques 

Module 4: Understanding Customer Needs

  • Importance of Understanding Customer Needs
  • Techniques for Gathering Customer Feedback
  • Analysing Customer Data
  • Creating Customer Personas 
  • Mapping Customer Journey
  • Identifying Touchpoints

Module 5: Developing Customer-Centric Strategies

  • Using Customer Insights to Inform Business Strategy
  • Creating Customer-Focused Mission Statements
  • Building a Customer-Centric Culture

Module 6: Measuring Customer Success

  • Overview of Customer Success Metrics
  • Net Promoter Score (NPS)
  • Customer Lifetime Value (CLV)
  • Customer Churn Rate

Module 7: Applying Lean Techniques to Customer Success

  • Using Lean Principles to Improve Customer Success
  • Creating Customer Success Plans
  • Implementing Customer Feedback Loops
  • Lean Marketing Techniques

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Who should attend this Advanced Lean Techniques and Understanding Customers Training   Course?

The Advanced Lean Techniques and Understanding Customers Training Course is designed for those who want to get better at understanding and implementing Lean methodologies for a customer-satisfaction. The Advanced Lean Techniques and Understanding Customers Training Course can benefit individuals such as:

  • Lean Practitioners
  • Operations Managers
  • Process Engineers
  • Manufacturing Engineers
  • Business Analysts
  • Senior Executives
  • Product Managers 

Prerequisites of the Advanced Lean Techniques and Understanding Customers Training Course

There are no formal prerequisites for this Advanced Lean Techniques and Understanding Customers Training Course.

Advanced Lean Techniques and Understanding Customers Training Course Overview

Advanced Lean techniques are a collection of principles and methodologies used to improve productivity, decrease waste, and streamline corporate operations. It is beneficial for enhancing organisational performance and improving financial outcomes. Studying this training provides individuals with useful information on customer preferences and needs, as well as market trends and competitor activities. This training helps organisations identify new market opportunities, develop new products and services, and improve customer satisfaction. Individuals with excellent Lean thinking will get tremendous job opportunities and claim desired earnings in high-demand positions at globally recognised organisations.

The Knowledge Academy’s 1-day Advanced Lean Techniques and Understanding Customers Training course provide delegates with in-depth knowledge about Lean thinking and its key principles in various industries. During this training, they will learn how to understand customer needs through customer feedback and data. They will also learn about the maintenance of equipment and machinery to prevent breakdowns. This course will be led by our highly skilled and knowledgeable trainer, who has years of experience in teaching and will help delegates get a complete understanding of this course. 

Course Objectives

  • To understand the importance of Lean thinking in modern business
  • To learn about how to implement advanced Lean techniques in real-world
  • To analyse customer data to meet their preferences and expectations
  • To create strategies for building a customer-centric culture
  • To implement customer feedback loops for improvement
  • To know Lean marketing techniques for improving customer satisfaction

After attending this training, delegates will be able to implement advanced Lean techniques in real-world scenarios to achieve tangible improvement results. They will also be able to create customer success plans and implement customer feedback loops to meet their needs and expectations.

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What’s included in this Introduction to Advanced Lean Techniques and Understanding Customers Training Course?

  • World-Class Training Sessions from Experienced Instructors
  • Advanced Lean Techniques and Understanding Customers Certificate
  • Digital Delegate Pack

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Online Instructor-led (1 days)

Online Self-paced (8 hours)

6S Training Course Outline

Module 1: Introduction to 6S Methodology

  • What Is 6S and Its Key Principles?
  • Benefits of Implementing 6S in the Workplace
  • What is 5s?
  • Understanding the Difference Between 5S and 6S
  • Overview of the 6S Implementation Process

Module 2: Sort (Seiri)

  • Importance of Workplace Organisation and Decluttering
  • Identifying and Categorising Necessary Vs. Unnecessary Items
  • Methods for Disposing of Unneeded Items Responsibly
  • Developing a Sustainable Sorting Process

Module 3: Set in Order (Seiton)

  • Organising and Arranging Essential Items Efficiently
  • Creating a Logical and Ergonomic Layout
  • Implementing Visual Cues
  • Establishing Standards

Module 4: Shine (Seiso)

  • Understanding the Significance of Cleanliness and Hygiene
  • Developing a Cleaning Schedule and Responsibilities
  • Implementing an Effective Cleaning Process
  • Maintaining a Clean and Safe Work Environment

Module 5: Standardise (Seiketsu)

  • Creating Standard Operating Procedures (SOPs)
  • Establishing Guidelines
  • Apply Tools and Techniques
  • Auditing and Measuring 6S

Module 6: Sustain (Shitsuke)

  • Developing Strategies
  • Empowering Employees to Take Ownership of 6S Initiatives
  • Encouraging a Culture of Discipline and Accountability
  • Addressing Challenges and Overcoming Barriers to Sustain 6S

Module 7: Safety and 6S

  • Integrating Safety Measures Within the 6S Methodology
  • Identifying Potential Safety Hazards and Risks
  • Promoting a Safety-First Mindset in the Workplace
  • Health and Safety Regulations

Module 8: Applying 6S Beyond the Workplace

  • Implementing 6S Principles
  • Utilising 6S for Improving Workflows and Processes
  • Overcoming Resistance to Change and Fostering a 6S Culture

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Who should attend this 6S Training Course?

This 6S Training course is suitable for those who want to optimise workplace organisation and processes effectively. This course is beneficial for various professionals including:

  • Manufacturing Workers
  • Warehouse and Logistics Personnel
  • Operations Managers
  • Production Supervisors
  • Maintenance Technicians
  • Lean Practitioners
  • Safety Managers
  • Facility Managers

Prerequisites for the 6S Training Course

There are no formal prerequisites for attending this 6S Training Course.

6S Training Course Overview

6S is a process to create a well-structured, clean, and high-performance workplace in a safe environment conducive to improved productivity and employee well-being. It aims to assist individuals in creating consistent work routines across their processes and forming more productive habits. 6S Training Course equips organisations with the tools and knowledge to successfully implement 6S principles throughout their workplaces. By pursuing this training, individuals will learn how to work smarter, stay focused, and maintain a clutter-free and well-organised workspace. This training can lead them to enhance their professional skills and increase opportunities for leadership roles in the organisation.

During this 1-day 6S Training Course, delegates will learn the significance of each 6S principle and how to implement them effectively to create an efficient and well-structured work environment. They will also learn the importance of workplace cleanliness, decluttering, and safety measures to enhance productivity and employee well-being. Delegates will learn how to develop sustainable sorting processes, arrange tools and equipment logically, and establish standard operating procedures for maintaining orderliness. This training will be conducted by our highly professional and skilled trainer, who has years of experience in teaching.

Course Objectives

  • To understand the importance of workplace organisation and cleanliness
  • To implement 6S principles effectively for enhanced workplace efficiency
  • To develop sustainable sorting and organising processes in workplaces
  • To establish Standard Operating Procedures (SOPs) for maintaining orderliness
  • To foster a culture of continuous improvement and employee engagement
  • To become familiar with valuable skills for maintaining clutter-free workspaces

At the end of this 6S Training Course, delegates will be able to create Standard Operating Procedures (SOPs) to maintain orderliness and cleanliness consistently. They will also be able to transform their workplaces into more organised, efficient, and productive spaces, contributing to the overall success and well-being of their organisations.

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What’s included in this 6S Training Course?

  • World-Class Training Sessions from Experienced Instructors
  • 6S Certificate
  • Digital Delegate Pack

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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.

Lean Training FAQs

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 for Lean Training.
The price for Lean Training certification in Philippines starts from $1495.

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