Operational Excellence - Lean Manufacturing

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Lean Training Courses

Below is a series of Lean training courses that have proven effective in many global industries. The content reflects the best practices of Lean enterprise implementation in the automotive, aerospace, chemical and information industries and includes worksheets and training strategies. All courses are sold in editable format (PowerPoint, Excel and Word).

 To order, please call 864-315-9210 for a free PDF example of your course.

Lean Training Curriculum


6 S

 6S is a workplace organization method that uses a list of five Japanese concepts translated as "Sort", "Set In order", "Shine", "Standardize" and "Sustain". The list describes how to organize a work space for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items, and sustaining the new order. In some quarters, 5S has become 6S, the sixth element being safety.


24 PP slides including worksheets and implementation strategy 


7 Wastes

  The 7 Wastes are categories of unproductive manufacturing practices identified by Taiichi Ohno, the father of the Toyota Production System (TPS). The categories are an integral part of the TPS (known as lean production in North America).

16 PP slides including 2 implementation worksheets 


Standard Work

Standard Work is a collection and implementation of the best practices known to that point. Because improvements in quality, safety, and productivity will appear from time to time the standard work is to be updated via work instruction document, training, and practice.

14 PP slides including a shop floor implementation template


Visual Factory

The visual workplace is a continuous improvement paradigm that offers its own comprehensive methodology for significant financial and cultural improvement gains. This system integrates and codifies the many iterations of visual factory in the world of continuous improvement.

23 pp slides with multiple examples


Problem Solving

Lean Problem-Solving training consists of two tools. Five whys (or 5 whys) is an iterative interrogative technique used to explore the cause-and-effect relationships underlying a particular problem. The primary goal of the technique is to determine the root cause of a defect or problem by repeating the question "Why?". Each answer forms the basis of the next question. The "five" in the name derives from an anecdotal observation on the number of iterations needed to resolve the problem. Ishikawa diagrams (also called fishbone diagrams, herringbone diagrams, or cause-and-effect diagrams) are causal diagrams created by Kaoru Ishikawa that show the causes of a specific event.

 Problem Solving for Supervisors 98 slides

 (32 hours of training) including worksheets 


Problem Solving Overview 13 slides (4 hours of training)


Value Stream Mapping

Value-stream mapping is a lean management method for analyzing the current state and designing a future state for the series of events that take a product or service from its beginning through to the customer with reduced lean wastes as compared to current map. A value stream focuses on areas of a firm that add value to a product or service, whereas a value chain refers to all of the activities within a company.

37 slides with 3 Excel examples



Single Minute Exchange of Die (SMED)

Single-Minute Exchange of Die (SMED) is one of the many lean production methods for reducing waste in a manufacturing process. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product.

43 PP slides with examples


Plan for Every Part (PFEP)

PFEP is a data base created to gather and maintain information about all parts, components, supplies, WIP inventories, raw materials, finished goods and any other form of material used in your processes PFEP data base must have sorting capabilities.

PFEP Overview  2 hours of training 23 PP slides (Overview)


PFEP - Full Shop floor Implementation Package (5 complete Courses) 48 hours of training 345 PP slides including 14 worksheets 


Process Failure Mode and Effects Analysis (PFMEA)

 Process  Failure Mode and Effects Analysis (PFMEA)—also "failure modes", is one of the first highly structured, systematic techniques for failure analysis. It was developed by reliability engineers in the late 1950s to study problems that might arise from malfunctions of military systems.

47 pp slides including 3 worksheets


Swim Lane Mapping

A Swim Lane Map is used in process flow diagrams, or flowcharts, that visually distinguishes job sharing and responsibilities for sub-processes of a business process. Swim lanes may be arranged either horizontally or vertically. Swim Lane Mapping is used to identify and eliminate waste in transactional processes (accounts payable, marketing, sales, finance, etc.)

21 PP slides with 3 examples and a template


Total Productive Maintenance (TPM)

  Total Productive Maintenance is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization. TPM focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes.

TPM Overview – 12 PP slides


           Full TPM Implementation Package (4 courses) 200 PP slides and 6 worksheets $4,000.                                                                                                                                         

Production Preparation Process (3P)

Lean experts typically view 3P as one of the most powerful and transformative advanced manufacturing tools, and it is typically only used by organizations that have experience implementing other lean methods. Whereas kaizen and other lean methods take a production process as a given and seek to make improvements, the Production Preparation Process (3P) focuses on eliminating waste through product and process design.

6 PP slides and examples



Design for Assembly / Manufacturability

  Design for assembly / manufacturability is the general engineering practice of designing products in such a way that they are easy to manufacture. The concept exists in almost all engineering disciplines, but the implementation differs widely depending on the manufacturing technology. DFM describes the process of designing or engineering a product in order to facilitate the manufacturing process in order to reduce its manufacturing costs.

               27 slides with an implementation schedule


Lean Plant Assessment

This assessment helps to investigate, evaluate, and measure nine key areas of manufacturing. The result is a deeper understanding of key issues, problem areas, and potential solutions.

Lean Assessment Package (Assessment Tool will all implementation worksheets)


Process Mapping

The Process Mapping tool allows the leader to analyze, identify and eliminate process wastes in specific operator workstations.

16 PP slides with 3 examples and templates