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Course: LEAN Manufacturing Tools

Duration: 4 Days Contact Time

Venue: In-House

Objectives and Benefits:

The objectives of this programme are designed to provide delegates with a detailed knowledge of the key tools involved in introducing LEAN Manufacturing.

The workshop will provide participants with the knowledge and skill to:

  • Enable the introduction of LEAN improvement activities in their area of responsibility.
  • Participate in the implementation of LEAN principles Company-Wide.


  • Decreased cycle time
  • Less inventory
  • Increased productivity
  • Increased capital equipment utilisation.

Participants: The Programme is aimed at company personnel in Materials, Quality, Engineering and Production. Each participant will be required to identify a LEAN Improvement Project.

Course Agenda:

Day 1

Unit 1 - Lean Thinking

  • History of Lean Manufacturing
  • Differences between Lean Manufacturing and Mass Production
  • The 5 Lean Principles
  • Understanding Value (in the eyes of the customer)
  • Recognizing the 7 wastes

Unit 2 - Takt Time and Standard Work

  • The benefits of a Standard Work System
  • The elements of Standard Work
  • Conducting Process Observation to determine element cycle times
  • Configuring Standard Work for minimum use of labour, materials and equipment
  • Documenting results on a Standard Work Chart

Day 2

Unit 3 - Lean Material Systems and Kanban

  • The benefits of a Kanban system
  • Selecting an appropriate Kanban system
  • Setting up a Kanban systems (calculating the number of cards required)
  • The benefits of a Timed Delivery route

Unit 4 - Improvement Cycles

  • Understanding the Plan-Do-Check-Act (PDCA) improvement cycle
  • Selecting appropriate improvement tools
  • Distinguishing between Root causes, Direct causes and Contributory causes
  • Identifying appropriate Corrective and Preventive actions
  • Construct a problem definition and SMART objectives
  • Differences between Incremental and Breakthrough Improvement

Unit 5 - Value Stream Mapping

  • The benefits of Value Stream Mapping
  • The four stages of Value Stream Mapping
  • Selecting appropriate products/product families
  • Creating the Current State Value Stream Map
  • Assessing the Current State Value Stream Map
  • Developing the Future State Value Stream Map
  • Creating an action plan to achieve the desired improvements

Day 3

Unit 6 - Lean Foundations

  • The benefits of Workplace Organisation
  • Implementing 5S Workplace Organisation
  • Implementing appropriate Visual Control Systems
  • The benefits of Total Productive Maintenance (TPM)
  • Understanding the elements of the Overall Equipment Effectiveness (OEE) metric
  • Implementing a basic Total Productive Maintenance (TPM) system to improve Overall Equipment Effectiveness (OEE)

Unit 7 - Quick Changeovers (The SMED System)

  • The benefits of a Single Minute Exchange of Die (SMED) System
  • The four stages of SMED
  • Implementing SMED to reduce Changeover time

Unit 8 - Kaizen Events

  • The benefits of a Kaizen Events
  • Appropriate situations for a Kaizen Event
  • Selecting appropriate team-members
  • Identifying Kaizen Event goals
  • Participating in a Kaizen Event

Unit 9 - Quality, Mistake-proofing and Line Layout

  • Understanding the interaction between quality and lean manufacturing
  • The principles of Mistake-proofing
  • Selecting appropriate mistake proofing devices
  • Selecting or devising an appropriate line layout to minimise waste

Day 4

  • Project presentations
  • Skills demonstrations

Course Fee: Fees supplied on request - Contact Us

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