Lean Foundations Workshop
- Course Duration
- 2 Days
Need Group Training
Course Description
Struggling with bottlenecks, rework, or wasted time in your processes? You’re not alone; process inefficiencies cost companies up to 30% of their revenue each year.
The Lean Foundations Workshop gives you the tools to change that. In just two days, you’ll go beyond theory and dive into real-world Lean techniques through an immersive Kaizen simulation. You’ll learn how to identify the root causes of inefficiency, eliminate waste, and boost the flow of value across any process, whether in operations, manufacturing, healthcare, or office workflows.
Led by expert instructors, this hands-on workshop introduces powerful tools like 5S, value stream mapping, and root cause analysis. You’ll leave with a practical Lean toolkit and a customized action plan to start improving processes immediately. Plus, you’ll earn 19.5 PDUs to help maintain your professional credentials.
Course Objective
After completing this course, participants will be able to define value from the customer’s perspective, map value streams, quantify flow, and remove waste using proven Lean tools and behaviors. Graduates return ready to facilitate improvements, sustain gains, and build momentum for a Lean culture.
- Explain Lean principles and distinguish value-add vs. non–value-add work
- Create current- and future-state value stream maps to visualize flow
- Measure and interpret takt time, cycle time, lead time, WIP, and throughput
- Identify and reduce the eight wastes (muda), using 5 Whys and cause-and-effect
- Apply 5S, visual management, standard work, and basic Kanban/WIP limits
- Plan and facilitate a focused Kaizen/PDCA improvement effort and sustain results
Course Outline
Module 1: Lean Principles & Mindset
- Origins of Lean and the Toyota Production System
- Customer value vs. non–value-add work
- The eight wastes (muda) and waste-walk techniques
- Lean, Six Sigma, and Agile—where each fits
Module 2: Mapping the Value Stream & Core Metrics
- Process mapping vs. value stream mapping (VSM)
- Current-state vs. future-state design
- Takt time, cycle time, lead time, WIP, and bottlenecks
- Introduction to Little’s Law and flow efficiency
Module 3: Finding & Eliminating Waste
- Gemba walks and structured observation
- Root cause analysis (5 Whys, fishbone)
- Quick wins, prioritization, and impact–effort grids
- Changeover basics (SMED-lite concepts)
Module 4: Flow, Pull, and Work Design
- Batch size, flow, and line balancing
- Kanban signals and setting WIP limits
- Standard work and visual work instructions
- Level loading (heijunka) fundamentals
Module 5: Quality at the Source & Visual Management
- Error-proofing (poka-yoke) and andon
- 5S and workplace organization
- Daily huddles and tiered escalation
- Visual controls and performance boards
Module 6: Kaizen & Sustainment
- PDCA and A3 problem solving
- Planning and running a Kaizen event
- Control plans and sustaining gains
- Coaching behaviors and change adoption
Module 7: Measuring Results & Roadmap
- Selecting KPIs (lead time, throughput, FTQ, OEE overview)
- Baselines, dashboards, and review cadence
- Before/after storytelling and benefits tracking
- 30/60/90-day improvement roadmap