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Lean Manufacturing

Workshop Overview

The Lean training program has been designed to provide personnel from a cross-function of departments the skills and techniques to implement standardized work cells in your Production facility. The Lean Training program has been designed to be provided in 2 phases.

The first phase is Classroom Training in the Lean tools that will be delivered to your  key management, support, and operational personnel who will need to understand and support the Lean principles and techniques, such as:


        Takt Time

        Buffer & Safety Inventory

        Continuous Flow, Just-In-Time, product flow

        Line Balancing


        Quick Changeovers (also called Single Minute Exchange of Dies SMED)

        Total Productive Maintenance

        Paced Withdrawal



The second phase is Application Training, where one or more project teams, of approximately 5 personnel in each team, will apply the Lean tools that they have learned, under the guidance of the trainer.

JM_Value Stream Management

Workshop Content

The Lean Training program has been designed to be provided in 2 phases.

      The first phase of the Lean Training program, Classroom Training, is built around the 7 Value Stream Management steps needed to plan, map, and sustain lean improvements. The seven steps are:

        Step 1: Commit to Lean this includes assigning a champion and team to a value stream, and defining the vision and goals for the team through a project charter prepared by the team and confirmed by management

        Step 2: Choose the Value Stream this involves targeting a product/product family (the value stream) to eliminate waste and improve overall material & information flow

        Step 3: Map the Current State the team will learn how to prepare a Current State Value Stream Map.

        Step 4: Identify Lean Metrics the easiest way to get people to contribute to Lean initiatives is to give them a simple means of understanding the impact of their efforts as they improve their value stream. Lean metrics provide such a means, thus helping to drive continuous improvement and waste elimination.

        Step 5: Map the Future State there are 3 stages for future-state mapping; customer demand, continuous flow, and leveling. In step 5 we introduce the teams to the bulk of the Lean tools & techniques. Topics include 5S, Takt Time, Buffer & Safety Inventory, JIT, Line Balancing, Kanban, Quick Changeovers (SMED), Total Productive Maintenance (TPM), Paced Withdrawal and Heijunka. These and other tools will give us the concepts needed to prepare a Future State Value Stream Map.

        Step 6: Create Kaizen Plans a kaizen plan is a call to action; the details of the actions, responsibilities and timelines to achieve the future state. A key element in this step is to create a Storyboard that communicates the lean journey; the storyboard is prepared in this step.

        Step 7: Implement Kaizen Plans Just Do It! And then document the improvements achieved in the lean metrics

      The second phase is Application Training, conducted at your facility, where the project team(s) will apply the 7-step Value Stream Management process that they have learned in the classroom sessions, under the guidance of the trainer.

         There is typically between 10 to 15 days of Application Training


You Need to Attend This Workshop If ......

  • You want to see dramatic improvements in your manufacturing processes
  • You want to apply Lean techniques to key product lines under the guidance of a lean facilitator
  • You want to introduce "Lean Thinking" to your organization

Call PQA to discuss your training needs at:+1 (519)-667-1720  or in N.America (800)-837-7046


Email:  dwhitred@pqa.net

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