Lean Manufacturing Awareness Training Course
Comprehensive LEAN Manufacturing Awareness training aligned with ISO 9001 and TPS principles.
Course Title
LEAN Manufacturing Awareness
Course Duration
1 Day
Competency Assessment Criteria
Practical Assessment and Knowledge Assessment
Training Delivery Method
Classroom (Instructor-Led) or Online (Instructor-Led)
Service Coverage
Saudi Arabia - Bahrain - Kuwait - Philippines
Course Average Passing Rate
99%
Post Training Reporting
Post Training Report(s) + Candidate(s) Training Evaluation Forms
Certificate of Successful Completion
Certification is provided upon successful completion. The certificate can be verified through a QR-Code system.
Certification Provider
Tamkene Saudi Training Center - Approved by TVTC (Technical and Vocational Training Corporation)
Certificate Validity
2 Years (Extendable with additional training hours)
Instructors Languages
English / Arabic / Urdu / Hindi / Pashto
Training Services Design Methodology
ADDIE Training Design Methodology
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Course Overview
This comprehensive LEAN Manufacturing Awareness training course provides participants with essential knowledge and practical skills required for identifying and eliminating waste while maximizing value creation in manufacturing processes. The course covers fundamental LEAN principles along with advanced techniques for implementing continuous improvement, value stream mapping, and operational excellence.
Participants will learn to apply Toyota Production System (TPS) methodologies and ISO 9001 quality management standards to ensure sustainable process improvement throughout various manufacturing environments. This course combines theoretical concepts with practical applications and real-world case studies to ensure participants gain valuable skills applicable to their professional environment while emphasizing operational efficiency and customer value delivery.
Key Learning Objectives
Understand fundamental LEAN manufacturing principles and waste identification techniques
Apply value stream mapping and process flow analysis methodologies
Implement 5S workplace organization and visual management systems
Develop effective continuous improvement and problem-solving strategies
Support operational excellence through standardized work and error-proofing methods
Apply LEAN tools and techniques for process optimization and efficiency enhancement
Evaluate performance metrics and measurement systems for LEAN implementation
Implement change management and employee engagement strategies
Group Exercises
Waste identification workshop including (gemba walk simulation, process observation, improvement opportunity mapping)
5S implementation simulation including (workplace organization, visual management, standardization development)
Knowledge Assessment
LEAN principles including (waste types, value identification, continuous improvement concepts)
Tool application including (5S implementation, Kanban systems, Kaizen methods)
Course Outline
1. Introduction to LEAN Manufacturing
LEAN fundamentals including (value creation, waste elimination, continuous flow, customer focus)
Toyota Production System (TPS) principles including (Just-in-Time, Jidoka, respect for people, continuous improvement)
Business benefits including (cost reduction, quality improvement, delivery performance, employee engagement)
2. Eight Wastes Identification and Elimination
Muda (waste) types including (overproduction, waiting, transportation, over-processing, inventory excess)
Muri and Mura including (overburden, unevenness, demand variation, production fluctuation)
Waste identification techniques including (gemba walks, value stream analysis, process observation)
3. 5S Workplace Organization System
5S implementation including (Sort, Set in Order, Shine, Standardize, Sustain)
Visual management including (workplace organization, tool placement, cleaning standards, sustainability practices)
Implementation strategies including (red tag strategy, documentation, audit systems, culture change)
4. LEAN Tools and Techniques
Kanban pull systems including (card systems, signal methods, inventory control, production scheduling)
Kaizen continuous improvement including (small incremental changes, employee suggestions, problem-solving cycles)
Poka-Yoke error-proofing including (mistake prevention, detection methods, process design, quality assurance)
5. HSE in LEAN Manufacturing
Safety integration including (hazard identification, risk assessment, safe work practices, incident prevention)
Environmental considerations including (waste reduction, energy efficiency, resource conservation, pollution prevention)
Ergonomic improvements including (workstation design, repetitive motion reduction, worker comfort)
6. Quality Assurance in LEAN Manufacturing
ISO 9001 quality management including (process approach, customer focus, continuous improvement, evidence-based decisions)
Quality integration including (defect prevention, inspection optimization, customer satisfaction, supplier quality)
Problem-solving methodologies including (root cause analysis, corrective actions, preventive measures)
7. Case Studies & Group Discussions
Regional manufacturing implementations including (automotive assembly, electronics production, food processing, textile operations)
Successful LEAN transformations including (cost savings achievements, quality improvements, delivery enhancements)
The importance of proper training in developing LEAN manufacturing capabilities and sustaining operational improvements
Practical Assessment
Waste elimination project including (identification methods, improvement strategies)
Workplace organization exercise including (5S implementation, visual management)
Gained Core Technical Skills
Comprehensive LEAN manufacturing principles using Toyota Production System (TPS) methodologies
Advanced waste identification and elimination techniques for operational efficiency improvement
Value stream mapping and process analysis for flow optimization and lead time reduction
5S workplace organization system implementation for visual management and standardization
Continuous improvement facilitation using Kaizen and problem-solving methodologies
Performance measurement and monitoring systems for sustained LEAN implementation
Training Design Methodology
ADDIE Training Design Methodology
Targeted Audience
Manufacturing Engineers working in production environments
Production Supervisors managing manufacturing operations
Quality Assurance Personnel ensuring product excellence
Process Improvement Specialists leading operational enhancement
Operations Managers overseeing manufacturing performance
Maintenance Personnel supporting production systems
Team Leaders facilitating continuous improvement activities
Technical Personnel involved in manufacturing optimization
Why Choose This Course
Comprehensive coverage of LEAN manufacturing from fundamental principles to practical implementation
Integration of Toyota Production System with ISO 9001 quality management standards
Focus on practical waste elimination and value creation techniques
Hands-on exercises with real manufacturing scenarios and improvement simulations
Exposure to proven LEAN tools and continuous improvement methodologies
Emphasis on sustainable change management and employee engagement strategies
Opportunity to learn from successful regional manufacturing transformation cases
Development of critical skills for operational excellence and competitive advantage
Note
Note: This course outline, including specific topics, modules, and duration, is subject to change and also can be customized based on the specific needs and requirements of the client.
Course Outline
1. Introduction to LEAN Manufacturing
LEAN fundamentals including (value creation, waste elimination, continuous flow, customer focus)
Toyota Production System (TPS) principles including (Just-in-Time, Jidoka, respect for people, continuous improvement)
Business benefits including (cost reduction, quality improvement, delivery performance, employee engagement)
2. Eight Wastes Identification and Elimination
Muda (waste) types including (overproduction, waiting, transportation, over-processing, inventory excess)
Muri and Mura including (overburden, unevenness, demand variation, production fluctuation)
Waste identification techniques including (gemba walks, value stream analysis, process observation)
3. 5S Workplace Organization System
5S implementation including (Sort, Set in Order, Shine, Standardize, Sustain)
Visual management including (workplace organization, tool placement, cleaning standards, sustainability practices)
Implementation strategies including (red tag strategy, documentation, audit systems, culture change)
4. LEAN Tools and Techniques
Kanban pull systems including (card systems, signal methods, inventory control, production scheduling)
Kaizen continuous improvement including (small incremental changes, employee suggestions, problem-solving cycles)
Poka-Yoke error-proofing including (mistake prevention, detection methods, process design, quality assurance)
5. HSE in LEAN Manufacturing
Safety integration including (hazard identification, risk assessment, safe work practices, incident prevention)
Environmental considerations including (waste reduction, energy efficiency, resource conservation, pollution prevention)
Ergonomic improvements including (workstation design, repetitive motion reduction, worker comfort)
6. Quality Assurance in LEAN Manufacturing
ISO 9001 quality management including (process approach, customer focus, continuous improvement, evidence-based decisions)
Quality integration including (defect prevention, inspection optimization, customer satisfaction, supplier quality)
Problem-solving methodologies including (root cause analysis, corrective actions, preventive measures)
7. Case Studies & Group Discussions
Regional manufacturing implementations including (automotive assembly, electronics production, food processing, textile operations)
Successful LEAN transformations including (cost savings achievements, quality improvements, delivery enhancements)
The importance of proper training in developing LEAN manufacturing capabilities and sustaining operational improvements
Why Choose This Course?
Comprehensive coverage of LEAN manufacturing from fundamental principles to practical implementation
Integration of Toyota Production System with ISO 9001 quality management standards
Focus on practical waste elimination and value creation techniques
Hands-on exercises with real manufacturing scenarios and improvement simulations
Exposure to proven LEAN tools and continuous improvement methodologies
Emphasis on sustainable change management and employee engagement strategies
Opportunity to learn from successful regional manufacturing transformation cases
Development of critical skills for operational excellence and competitive advantage
Note: This course outline, including specific topics, modules, and duration, is subject to change and also can be customized based on the specific needs and requirements of the client.
Practical Assessment
Waste elimination project including (identification methods, improvement strategies)
Workplace organization exercise including (5S implementation, visual management)
Course Overview
This comprehensive LEAN Manufacturing Awareness training course provides participants with essential knowledge and practical skills required for identifying and eliminating waste while maximizing value creation in manufacturing processes. The course covers fundamental LEAN principles along with advanced techniques for implementing continuous improvement, value stream mapping, and operational excellence.
Participants will learn to apply Toyota Production System (TPS) methodologies and ISO 9001 quality management standards to ensure sustainable process improvement throughout various manufacturing environments. This course combines theoretical concepts with practical applications and real-world case studies to ensure participants gain valuable skills applicable to their professional environment while emphasizing operational efficiency and customer value delivery.
Key Learning Objectives
Understand fundamental LEAN manufacturing principles and waste identification techniques
Apply value stream mapping and process flow analysis methodologies
Implement 5S workplace organization and visual management systems
Develop effective continuous improvement and problem-solving strategies
Support operational excellence through standardized work and error-proofing methods
Apply LEAN tools and techniques for process optimization and efficiency enhancement
Evaluate performance metrics and measurement systems for LEAN implementation
Implement change management and employee engagement strategies
Knowledge Assessment
LEAN principles including (waste types, value identification, continuous improvement concepts)
Tool application including (5S implementation, Kanban systems, Kaizen methods)
Targeted Audience
Manufacturing Engineers working in production environments
Production Supervisors managing manufacturing operations
Quality Assurance Personnel ensuring product excellence
Process Improvement Specialists leading operational enhancement
Operations Managers overseeing manufacturing performance
Maintenance Personnel supporting production systems
Team Leaders facilitating continuous improvement activities
Technical Personnel involved in manufacturing optimization
