LEAN Manufacturing Training Course
LEAN Manufacturing Training aligned with TPS Toyota Production System, 5S Methodology, and ISO 9001 standards.
Course Title
LEAN Manufacturing
Course Duration
2 Days
Competency Assessment Criteria
Practical Assessment and knowledge Assessment
Training Delivery Method
Classroom (Instructor-Led) or Online (Instructor-Led)
Service Coverage
In Tamkene Training Center or On-Site: Covering Saudi Arabia (Dammam - Khobar - Dhahran - Jubail - Riyadh - Jeddah - Tabuk - Madinah - NEOM - Qassim - Makkah - Any City in Saudi Arabia) - MENA Region
Course Average Passing Rate
98%
Post Training Reporting
Post Training Report + 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
Training Services Design Methodology
ADDIE Training Design Methodology
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Course Overview
This comprehensive LEAN Manufacturing Training course provides participants with essential knowledge and practical skills required for implementing LEAN principles and continuous improvement methodologies in manufacturing and operational environments. The course covers fundamental LEAN concepts along with hands-on techniques for waste identification, process optimization, and value stream improvement.
Participants will learn to apply TPS Toyota Production System, 5S Methodology, ISO 9001 Quality Management Systems, and Kaizen Continuous Improvement principles to ensure operational excellence and waste elimination. This course combines theoretical LEAN concepts with practical hands-on training and real-world application scenarios to ensure participants gain valuable skills applicable to their operational environment while emphasizing customer value creation and process efficiency.
Key Learning Objectives
Understand LEAN manufacturing fundamentals and Toyota Production System (TPS) principles
Implement effective waste identification and elimination techniques using Seven Wastes methodology
Apply 5S Methodology for workplace organization and visual management
Execute Value Stream Mapping (VSM) for process analysis and improvement
Develop Kaizen continuous improvement and problem-solving capabilities
Apply appropriate Just-In-Time (JIT) and pull system implementation
Implement Standard Work and process standardization procedures
Apply LEAN metrics and performance measurement for operational excellence
Group Exercises
Value stream maps including (current state documentation, future state design, implementation roadmaps)
5S audit checklists including (assessment criteria, scoring methods, improvement tracking)
Kaizen project plans including (problem definition, improvement objectives, implementation schedules)
Standard work documentation including (work sequences, cycle times, quality standards)
Knowledge Assessment
LEAN fundamentals evaluations including (TPS principles, waste identification, customer value concepts)
Seven Wastes recognition exercises including (waste categorization, identification techniques, elimination strategies)
5S implementation assessments including (methodology application, workplace organization, visual management)
VSM development testing including (current state mapping, future state design, improvement identification)
Course Outline
1. LEAN Manufacturing Fundamentals and TPS Principles
LEAN philosophy including (customer value focus, waste elimination, continuous improvement, respect for people)
Toyota Production System (TPS) including (JIT production, Jidoka quality, respect for humanity, continuous improvement)
LEAN principles including (value definition, value stream identification, flow creation, pull establishment, perfection pursuit)
Customer Value including (value-added activities, non-value-added activities, customer requirements, quality standards)
2. Waste Identification and Seven Wastes Methodology
Seven Wastes (Muda) including (overproduction, waiting, transportation, over-processing, inventory, motion, defects)
Eighth Waste including (underutilized human potential, creativity waste, skill underutilization, knowledge gaps)
Waste Identification techniques including (observation methods, process mapping, time studies, root cause analysis)
Waste Elimination strategies including (process redesign, automation, standardization, error prevention)
3. 5S Methodology and Workplace Organization
5S Implementation including (Sort, Set in Order, Shine, Standardize, Sustain)
Visual Management including (visual controls, color coding, labeling systems, shadow boards)
Workplace Organization including (tool placement, material flow, safety integration, efficiency improvement)
5S Auditing including (assessment criteria, scoring systems, improvement tracking, sustainability measures)
4. Value Stream Mapping and Process Analysis
Value Stream Mapping (VSM) including (current state mapping, future state design, implementation planning)
Process Flow Analysis including (cycle time measurement, lead time reduction, bottleneck identification, capacity analysis)
Information Flow including (communication mapping, decision points, data requirements, feedback loops)
Improvement Opportunities including (waste elimination, flow enhancement, cycle time reduction, quality improvement)
5. Kaizen and Continuous Improvement Implementation
Kaizen Philosophy including (small incremental changes, employee involvement, continuous improvement culture)
Kaizen Events including (rapid improvement workshops, cross-functional teams, problem-solving focus)
Problem-Solving Tools including (5-Why Analysis, Fishbone Diagram, Pareto Analysis, Root Cause Analysis)
Improvement Tracking including (performance metrics, before-after comparisons, sustainability monitoring, lesson documentation)
6. Standard Work and Performance Measurement
Standard Work including (work sequence documentation, cycle time standards, work-in-process levels)
Just-In-Time (JIT) including (pull systems, kanban implementation, demand-driven production, inventory reduction)
Performance Metrics including (productivity measures, quality indicators, lead time tracking, customer satisfaction)
Continuous Monitoring including (performance dashboards, trend analysis, corrective actions, improvement planning)
Practical Assessment
Waste identification exercise including (workplace observation, waste categorization, elimination planning)
5S implementation demonstration including (sort activities, organization techniques, visual management setup)
VSM workshop including (process mapping, cycle time measurement, improvement opportunity identification)
Kaizen project simulation including (problem identification, root cause analysis, solution development)
Gained Core Technical Skills
Comprehensive LEAN manufacturing and TPS principle implementation capabilities
Seven Wastes identification and elimination methodology proficiency
5S workplace organization and visual management expertise
Value Stream Mapping (VSM) and process analysis competency
Kaizen continuous improvement and problem-solving technique application
Just-In-Time (JIT) and pull system implementation skills
Standard Work development and process standardization abilities
LEAN performance measurement and operational excellence management
Training Design Methodology
ADDIE Training Design Methodology
Targeted Audience
Manufacturing Engineers implementing LEAN principles
Production Supervisors leading operational improvements
Quality Assurance Personnel supporting LEAN initiatives
Operations Managers overseeing process optimization
Maintenance Technicians involved in LEAN implementation
Team Leaders facilitating continuous improvement
Process Improvement Specialists developing LEAN programs
Plant Personnel participating in LEAN transformation
Why Choose This Course
Essential LEAN manufacturing competency development
Comprehensive waste elimination methodology training
Practical continuous improvement skill building
Industry-recognized operational excellence principles
Professional LEAN implementation certification preparation
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. LEAN Manufacturing Fundamentals and TPS Principles
LEAN philosophy including (customer value focus, waste elimination, continuous improvement, respect for people)
Toyota Production System (TPS) including (JIT production, Jidoka quality, respect for humanity, continuous improvement)
LEAN principles including (value definition, value stream identification, flow creation, pull establishment, perfection pursuit)
Customer Value including (value-added activities, non-value-added activities, customer requirements, quality standards)
2. Waste Identification and Seven Wastes Methodology
Seven Wastes (Muda) including (overproduction, waiting, transportation, over-processing, inventory, motion, defects)
Eighth Waste including (underutilized human potential, creativity waste, skill underutilization, knowledge gaps)
Waste Identification techniques including (observation methods, process mapping, time studies, root cause analysis)
Waste Elimination strategies including (process redesign, automation, standardization, error prevention)
3. 5S Methodology and Workplace Organization
5S Implementation including (Sort, Set in Order, Shine, Standardize, Sustain)
Visual Management including (visual controls, color coding, labeling systems, shadow boards)
Workplace Organization including (tool placement, material flow, safety integration, efficiency improvement)
5S Auditing including (assessment criteria, scoring systems, improvement tracking, sustainability measures)
4. Value Stream Mapping and Process Analysis
Value Stream Mapping (VSM) including (current state mapping, future state design, implementation planning)
Process Flow Analysis including (cycle time measurement, lead time reduction, bottleneck identification, capacity analysis)
Information Flow including (communication mapping, decision points, data requirements, feedback loops)
Improvement Opportunities including (waste elimination, flow enhancement, cycle time reduction, quality improvement)
5. Kaizen and Continuous Improvement Implementation
Kaizen Philosophy including (small incremental changes, employee involvement, continuous improvement culture)
Kaizen Events including (rapid improvement workshops, cross-functional teams, problem-solving focus)
Problem-Solving Tools including (5-Why Analysis, Fishbone Diagram, Pareto Analysis, Root Cause Analysis)
Improvement Tracking including (performance metrics, before-after comparisons, sustainability monitoring, lesson documentation)
6. Standard Work and Performance Measurement
Standard Work including (work sequence documentation, cycle time standards, work-in-process levels)
Just-In-Time (JIT) including (pull systems, kanban implementation, demand-driven production, inventory reduction)
Performance Metrics including (productivity measures, quality indicators, lead time tracking, customer satisfaction)
Continuous Monitoring including (performance dashboards, trend analysis, corrective actions, improvement planning)
Why Choose This Course?
Essential LEAN manufacturing competency development
Comprehensive waste elimination methodology training
Practical continuous improvement skill building
Industry-recognized operational excellence principles
Professional LEAN implementation certification preparation
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 identification exercise including (workplace observation, waste categorization, elimination planning)
5S implementation demonstration including (sort activities, organization techniques, visual management setup)
VSM workshop including (process mapping, cycle time measurement, improvement opportunity identification)
Kaizen project simulation including (problem identification, root cause analysis, solution development)
Course Overview
This comprehensive LEAN Manufacturing Training course provides participants with essential knowledge and practical skills required for implementing LEAN principles and continuous improvement methodologies in manufacturing and operational environments. The course covers fundamental LEAN concepts along with hands-on techniques for waste identification, process optimization, and value stream improvement.
Participants will learn to apply TPS Toyota Production System, 5S Methodology, ISO 9001 Quality Management Systems, and Kaizen Continuous Improvement principles to ensure operational excellence and waste elimination. This course combines theoretical LEAN concepts with practical hands-on training and real-world application scenarios to ensure participants gain valuable skills applicable to their operational environment while emphasizing customer value creation and process efficiency.
Key Learning Objectives
Understand LEAN manufacturing fundamentals and Toyota Production System (TPS) principles
Implement effective waste identification and elimination techniques using Seven Wastes methodology
Apply 5S Methodology for workplace organization and visual management
Execute Value Stream Mapping (VSM) for process analysis and improvement
Develop Kaizen continuous improvement and problem-solving capabilities
Apply appropriate Just-In-Time (JIT) and pull system implementation
Implement Standard Work and process standardization procedures
Apply LEAN metrics and performance measurement for operational excellence
Knowledge Assessment
LEAN fundamentals evaluations including (TPS principles, waste identification, customer value concepts)
Seven Wastes recognition exercises including (waste categorization, identification techniques, elimination strategies)
5S implementation assessments including (methodology application, workplace organization, visual management)
VSM development testing including (current state mapping, future state design, improvement identification)
Targeted Audience
Manufacturing Engineers implementing LEAN principles
Production Supervisors leading operational improvements
Quality Assurance Personnel supporting LEAN initiatives
Operations Managers overseeing process optimization
Maintenance Technicians involved in LEAN implementation
Team Leaders facilitating continuous improvement
Process Improvement Specialists developing LEAN programs
Plant Personnel participating in LEAN transformation