LEAN Manufacturing Awareness Training Course | Saudi Arabia

ACCREDITATIONS

Clients

Course Duration

1 Day

Training Delivery Method

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

Instructors Languages

English / Arabic / Urdu / Hindi / Pashto

Certification Provider

Tamkene Saudi Training Center - Approved by TVTC (Technical and Vocational Training Corporation)

Certificate Validity

2 Years (Extendable with additional training hours)

Course Average Passing Rate

99%

Competency Assessment Criteria

Practical Assessment and Knowledge Assessment

Post Training Reporting

Post Training Report(s) + Candidate(s) Training Evaluation Forms

Training Design Methodology

ADDIE Training Design Methodology

Certificate of Successful Completion

Certification is provided upon successful completion. The certificate can be verified through a QR-Code system.

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

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

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

Group Exercises

Waste identification workshop including (gemba walk simulation, process observation, improvement opportunity mapping)
5S implementation simulation including (workplace organization, visual management, standardization development)

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

Service Coverage

Saudi Arabia - Bahrain - Kuwait - Philippines

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

Practical Assessment

Waste elimination project including (identification methods, improvement strategies)
Workplace organization exercise including (5S implementation, visual management)

Knowledge Assessment

LEAN principles including (waste types, value identification, continuous improvement concepts)
Tool application including (5S implementation, Kanban systems, Kaizen methods)

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.

Recommended Courses

All Courses

Course Title