Lean Fundamentals

All types of service and manufacturing organizations that experience the following challenges:

  • Missed order dates
  • High product or service cost relative to the competition
  • Losing market share due to increased delivery time or cost problems
  • Limited production capacity – space is used by inventory
  • Lean concepts and tools and how they apply to all types of processes and industries
  • Use Lean methods and data to reduce costs, shorten cycle times, expand capacity, and improve productivity
  • How Lean and Six Sigma are highly complementary
  • Difference between successfully instilling Lean Thinking and running the next "Flavor of the Monthprogram
  • Get input from knowledgeable instructors regarding specific concerns and projects to start on a proven path to success

Please contact us for information about prerequisites.

Expected Duration
4 day


Lean is a systematic approach to identifying and eliminating the eight wastes – considered non-value-adding activities-through continuous improvement by flowing the product completely at the pull of the customer. The eight wastes are: waiting, defects, extra processing, inventory, excessive motion, transportation, over production, and underutilized employees.


Upon completion of this four-day program, attendees can submit a project for a Lean Agent certification.


1. Introduction

  • Course Overview
  • Introduction to Lean
  • Linkage to Six Sigma

2. Lean Mentality: Muda (Waste) Elimination

  • The Hidden Office/Factory
  • Seven Types of Waste
  • Eliminating Waste

3. Mapping the Value Stream

  • Value Stream Mapping
  • Different Types of Maps
  • Foundation for Lean Events

4. Lean Events

  • Kaizen
  • Running a Typical Five Day (or Shorter) Event

5. Constraints

  • Finding the Bottlenecks in a Process Flow

6. Flow and TAKT Time

  • Movement Through the Value Stream
  • Rate or Rhythm of Flow Through each Process

7. Pull Systems and Kanban

  • All Activity is Pulled by Customer Demand
  • Simple Visual Signals

8. 5S Implementation

  • A Systematic Approach to Organizing the Work Space
  • NOT Just Housekeeping!

9. Poka Yoke (Mistake Proofing)

  • Reducing the Opportunity for Human Errors to Affect the Process

10. Lean Management Principles

  • How to Make it Happen and Make it Last in an Organization

11. Job Instruction Training

  • Transferring Knowledge in a Quality Process



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