Lean Training Course Outline

Module 1 Continuous Improvement Tools

Continuous Improvement

Improvement Philosophies and Methodologies

Just-In-Time (JIT)

Thinking Revolution

Lean Manufacturing

20 Keys to Workplace Improvement

Measuring and Prioritizing the Improvements

Module 2 Material Flow and Facilities Layout

Layout Improvement

Signs and Reasons for a Need to Change the Layout

Theoretical Basis

One-Piece Flow

Main Types of Industrial Companies

Layout Types

Characteristic of the Traditional Layouts

Layout Design Methodology

Step 1 Formulate the Problem

Step 2 Analysis of the Problem

Step 3 Search for Alternatives

Step 4 Choose the Right Solution

Step 5 Specification of the Solution

Step 6 Design Cycle

Tools for Layout Study

Muther’s 8 Factors

Module 3 Material Flow and Design Of Cellular Layouts

The Assembly Line

Theoretical Basis

Mass Production

Flow or Assembly Lines

Cell Layout Design Justification

Basic Cells Design Nomenclature

Cell Design Methodology

Cell Design Tools

Line Balancing

Group Technology

Time Study

Leveling Production

Multifunctional Workers

Workforce Optimization

Module 4 Equipment Efficiency: Quality and Poka-Yoke


Theoretical Basis

Inspection and SQC (Statistical Quality Control)

From SQC To Zero Defects

Poka-Yoke Design Methodology

Module 5 Equipment Efficiency: Performance and Motion Study

Motion Study

Theoretical Basis

Motion Economy Principles

Motion Study Tools

Value Analysis

5W2H and 5-Why Methods

Worker-Machine Diagram

Machine-Worker Ratio

Machine-Machine Diagram

Module 6 Equipment Efficiency: Availability, Performance, and Maintenance

Equipment Maintenance

Theoretical Basis

Types of Maintenance

Maintenance Program Implementation

Getting Started

Corrective Maintenance Implementation

Preventive Maintenance Implementation

Autonomous Maintenance

TPM – Total Productive Maintenance

RCM – Reliability Centered Maintenance

Maintenance Tools

FMEA for Equipment


PM Analysis

Maintenance Management

Module 7 Equipment Efficiency: Availability, Quality, and SMED

Setup Process

Theoretical Basis

Basic Steps in a Setup Process

Traditional Strategies to Improve the Setup Process

SMED Methodology

Preliminary Stage

Stage 1 Separating Internal and External Set-Up

Stage 2 Converting Internal Set-Up to External Set-Up

Stage 3 Streamlining All Aspects of the Setup Process

SMED Tools

First Stage Tools

Second Stage Tools

Third Stage Tools

Zero Changeover

SMED Effects and Benefits

Easier Set-Up Process

On-Hand Stock Production

Workplace Tasks Simplification

Productivity and Flexibility

Economic Benefits

Module 8 Environment Improvements and the 5S

A Clean and Organized Workspace

5S Implementation Methodology

Getting Started

Common Steps in the Five Pillars

First Pillar: Sort

Second Pillar: Set in Order

Third Pillar: Shine

Fourth Pillar: Standardize

Fifth Pillar: Sustain

Implementation of the 5S in Offices

Applying 5S to Computers

5S Tools

Red-Tagging Strategy

Sign Strategy

Painting Strategy

Preventive Order

Preventive Shine

Promotion Tools

5S Benefits and Effects

Module 9 Other Improvement Keys

Human Resources Related Keys

Rationalizing the System

Improvement Team Activities

Empowering Workers to Make Improvements

Efficient Materials Use Related Keys

Developing Your Suppliers

Conserving Energy and Materials

Reducing Inventory

Visual Control-Related Keys



Technology Related Keys


Using Information Systems

Leading Technology and Site Technology