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Lean Principles and Techniques

We have listed below a selection of standard course modules from which we can build tailored learning programmes to meet your specific requirements. Please contact us to discuss how we could help to meet your organisation's training needs.

Module Title	Module Content	Business Benefits	Duration
Leading a Lean Programme	Lean concepts and principles Benefits of Lean Leadership roles Overview of key techniques Lean programme organisation Implementation steps Leadership styles and change management	Apply techniques in the right sequence Avoid initiative overload Focus effort to best effect Improve overall business performance Build a Lean culture	1 day
Lean Concepts and Principles	Value and the Value Stream Flow and pull systems Perfection as the benchmark Cellular operations Kaizen and team-based improvement	Increase productivity Reduce inventory Improve quality Reduce lead times Improve on-time delivery	3 days
Value Stream Mapping	Value and the Value Stream Mapping techniques Identifying value-adding steps Prioritising improvement opportunities Organising a mapping project	Visualise how value is created Identify non value-adding activities, delays and waste Highlight improvement opportunities Prioritise high-value improvements	2 days
Cellular Operations	Cell concepts and principles Flow, layout and balancing Flexibility - the agile cell Material supply and handling Planning, measurement and control	Cut lead times and inventory Increase productivity and flexibility Engage the shop floor work force Improve health, safety and job satisfaction	1 day
Kanban and Pull Systems	Kanban and other pull techniques Usage pattern analysis Trigger levels and transfer quantities Pull systems for high-variety products Pull systems and ERP	Understand where to use pull systems Make the right choice of pull techniques Stabilise flows, cut lead times, cut inventory and improve productivity Eliminate wasteful administration	1 day
Changeover Reduction	SMED techniques Internal & external set-up Set-up analysis techniques Principles of lean manufacturing Toyota production system Basic concepts Factors affecting changeover	Increase capacity & productivity without buying more equipment Be more flexible and agile with shorter lead times Understand the impact on cost and waste reduction How to apply the techniques yourself	1 day
Problem Solving	Problem solving framework Problem identification and analysis Root cause analysis techniques Brain storming and other creative techniques Developing solutions	Identify and understand problems more clearly Deal effectively with problems in unfamiliar areas Solve problems faster Generate better solutions	1 day
5S	5S - a foundation for quality and improvement What the 5Ss mean 5S techniques Planning and running a 5S programme	Eliminate waste Build pride in the workplace Improve plant maintenance Improve safety, quality and productivity Support continuous improvement	1 day
Quality Improvement Techniques	The role of quality in Lean Process charting Analysing non-conformances Root cause analysis Mistake proofing	Improve delivered quality Prevent recurring errors Improve process reliability Reduce quality costs Enhance customer satisfaction	1 day
Continuous Improvement (Kaizen)	Continuous Improvement concepts Overview of improvement techniques Direction and empowerment Programme management Selecting projects	Establish an effective programme Provide structure and direction Encourage creativity Make improvements that support your business strategy	1 day
Team Facilitation Skills	The role of the facilitator Motivation - what makes people tick Team roles, lifecycle and dynamics Interventions Handling difficult situations	Nurture team development Help teams to learn Develop their problem solving skills Solve problems quicker at lower cost Clarify goals and objectives Resolve conflicts constructively	1 day
Integrating Lean and ERP	Principles of Lean and ERP The role of planning in Lean Integrating ERP and Lean 5S applied to information Lean information processing	Make Lean and ERP work together Plan effectively for Lean production Minimise shop-floor paperwork Make your data earn its keep Streamline administration	2 days
The Lean Supply Chain	Analysing the extended Value Stream Identifying waste in the Supply Chain Distribution networks and transport Warehousing and inventory Planning and procurement	Choose the right techniques Synchronise material flow Improve flexibility and responsiveness Improve availability with less inventory Reduce waste and costs	1 day
The Lean Office	The Lean "information factory" Information flow and pull systems Cellular organisation 5S in the office Quality in the office	Improve flexibility and responsiveness Leverage the knowledge and experience of the workforce Break down "functional silos" Solve problems quicker at lower cost	1 day