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LEAN Manufacturing Training Course

LEAN Manufacturing Training aligned with TPS Toyota Production System, 5S Methodology, and ISO 9001 standards.

Main Service Location

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Course Title

LEAN Manufacturing

Course Duration

2 Days

Training Delivery Method

Classroom (Instructor-Led) or Online (Instructor-Led)

Assessment Criteria

Knowledge Assessment

Service Category

Training, assessment, and certification services.

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

Interactive Learning Methods

2 Years (Extendable with additional training hours)

Training Services Design Methodology

ADDIE Training Design Methodology

ADDIE Training Services Design Methodology (1).png

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)

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

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)

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

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.

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)

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, can be customized based on the specific needs and requirements of the client.

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