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Course Overview
Up to 60% of business processes are inefficient, wasting time and resources. Lean Foundations gives your team the tools to identify value, eliminate waste, and build a culture of continuous improvement. Through practical exercises and real-world examples, you’ll learn the core Lean principles—value, value stream, flow, pull, and perfection—and how to apply them to reduce lead time, improve quality, and increase throughput.
Who Should Attend
Operations managers, team leads, supervisors, process/continuous improvement specialists, manufacturing and production personnel, service delivery leaders, business analysts, and project managers who need a practical foundation in Lean methods to drive measurable performance gains.
Course Objectives
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