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Lean Practitioner Training Program - Face to Face

Our face-to-face training can be provided at our training venue or in-company at your site.
Enquire for in-company training

Course overview

By the end of this ‘hands-on’ Lean Practitioner Training Program individuals will be able to provide leadership and guidance to their teams to make local improvements using tried-and-tested lean tools and techniques specifically focused on deployment at the 'business unit (shop floor) level'. Included are the 7 ‘Basic’ Quality Tools and the 7 ‘New’ Tools.

The structured training program comprises three 2-day sessions delivered on-site over a period of 3- to 6-weeks. The program involves practical instruction and coaching to empower individuals to use Lean tools/techniques. Workshops and Projects feature prominently throughout.

The goal is to provide the individuals with practical guidance on how to become Lean Practitioners capable of deploying lean to the benefit of the organization.

Course details

The syllabus is always adjusted to match existing knowledge and the management structure of the organization involved. All workshops/projects are customised to meet in-house situations. As a minimum, the following topics are always included -

Principles of lean enterprise

  • Different approaches to lean - muda & mura

  • TPS (Toyota Production System)

  • Developing a ‘framework’ for lean deployment

Managing the implementing of lean

  • Implement lean - RADAR

  • Implementing lean - ‘results’

  • Implementing lean - ‘deployment roadmap’

  • Implementing lean - ‘assess and review’

5-S practice – systematic housekeeping the foundation of a lean enterprise

  • Product quality - work environment

  • 5-S practice - the ‘pillars’ of success!

  • Road-blocks and benefits of 5-S practice

  • 5‘S’ evaluation - where are we now?

  • Incorporating Safety - the ‘6th unwritten ‘S’

  • Sort - the first pillar of 5‘S’

Workshop-1 - conducting a ‘red-tag’ day in a designated work area

Identifying and eliminating waste

  • Avoiding waste - muda

  • Visualizing and identifying the 7 (+1) deadly wastes

  • Understanding waste - value-adding and non-value-adding activities

  • Understanding the importance of the ‘flow of goods’

  • Uncovering waste - gemba

  • Using ‘Waste-finding Checklists’

  • Analysing, classifying and eliminating waste

  • Identifying solutions for waste elimination

  • Focusing on the three ‘mus’ - Muda - Mura - Muri

Workshop-2 – identify a work area or value-stream and using TECTransnational’s checklists to systematically analyse for each of the 7-wastes and then eliminating them

5-S practice – set-in-order

  • Set-in-order – the second pillar of 5‘S’

  • Set in Order – link to Sort

  • Set in Order – avoids many wastes (link to Workshop-2)

  • Racks, storage bins, shadow boards

  • Principles of storage – jigs, tools, dies

  • Set-in-Order – neatness

Workshop-3 – focused on the previously ‘red-tagged’ work area or cell involving a “set-in-order” exercise

Value Stream mapping (VSM)

  • The ‘5-steps’ to perfecting the value-stream

  • Goal of value-stream mapping (as-is - should-be - could-be)

  • Developing a values stream map

  • establishing the ‘value-stream and mapping

  • analysing operations in the value-stream

  • verifying the reviewing the findings

  • establishing ‘lead-times’ and ‘cycle-times’

  • Creating the value stream map

  • process flow, material and information flow

  • establishing ‘lead times’ and ‘processing times’

  • Verify the ‘current state’ value stream map

  • Analysing and improving the current state

  • Analysing for ‘value’ and ‘waste’

  • Understanding and calculating fundamental value stream metrics

  • Making improvements using lean principles

  • Specifying the ‘future-state’ map - “what could be”

Workshop-4 – focused on a ‘family’ of products – creating/analysing a current state VSM then and developing a future-state VSM

5‘S’ – shine

  • Shine - third pillar of 5‘S’

  • Reasons for making shine habitual

  • The six steps to implement shine

  • Determining the shine targets (safety - waste - cleanliness)

  • Assigning shines responsibilities and defining shine areas

  • Specifying the shine methods, providing shine tools and implementation

  • Attending to ‘uncovered problems’ - using Clean/Inspection Checklists

Workshop-5 – conduct a Shine exercise and include a Shine Schedule and Clean/Inspection Checklist for a selected work area or cell

Visual Control

  • Using simple visual indicators

  • Using visual aids with team briefings

  • Display-boards, check-sheets + Andon

  • Visual display-board of lean (process-level) metrics

  • Operator-used check-sheets (shop-floor data collection)

  • Active high-profile Andon displays

  • Visual skills matrices (displayed in the work areas/cells)

  • Visual work area/cell production scheduling

  • Visual indication of job performance (target-actual, time and problem charts)

  • Involving supervisions and operators

  • Developing top management ‘cock-pits’ for displaying information

Workshop-6 – Implementing Visual Controls in a selected work area or cell - e.g. skills matrix; production scheduling; lean metrics; check-sheets for shop-floor data collection; etc.

5‘S’ – standardize

  • Standardize – fourth pillar of 5‘S’

  • Standardizing all visual controls

  • Developing colour-coded factory floor areas

  • floor colours, lines and direction

  • aisles and traffic flows

  • danger areas and warnings

  • tools location – shadow board

  • locations and objects – boundaries/labels

  • location indicators on shelving units (stock-level indicators)

  • Roles, responsibilities and training

  • Continuous improvement focused on standardization

Standard Work/Job

  • Understanding and defining ‘standard work’

  • Characteristics of standard work – the five elements of standard work/job

  • Controlled conditions – documentation

  • Standard work/job – typical input documentation

  • Developing the culture of standard work/job and CI

  • Creating visual standard work/job instructions – including safety!

  • Develop work/job instructions for operators with operators

  • The ‘TWI 4-step learning’ process – supervisor led training

Workshop-7 – developing standard work/job instructions for a selected (current) product

5‘S’ - sustain

  • Sustain - fifth pillar of 5‘S’

  • Creating ‘unconscious competence’

  • Proactively identifying things that can go wrong!

  • Planning and undertaking value-adding 5‘S’ audits

  • Creating conditions or structures

  • Understanding ‘autonomous maintenance’

  • 5’S’ Display-boards, Posters and Slogans

  • Assessing the 5-levels of 5‘S’ achievement

  • 5‘S’ problem and suggestion maps

  • Extending the 5‘S’ concept to Engineering, Inventory, Suppliers, IT and Finance

  • Engineering, Inventory, Suppliers, IT and Finance

  • Celebrating 5‘S’ success stories - creating 'team boards' and ‘storyboards’

Workshop-8 – conducting a 5‘S’ audit using a Checklist with associated Scoring

The Quality Tools

This extended session addresses the principles and practices included in the 7 'basic' quality tools and the 7 'new' quality tools.

Each tool is considered in details to ensure that students are 'empowered' to use the tool in the appropriate situation - correctly!

The 7 'Basic' Quality Tools

  1. Cause-and-effect diagram

  2. Check sheet

  3. Control charts

  4. Histogram

  5. Pareto chart

  6. Scatter diagram

  7. Stratification

  8. Process flow

Seven 'New' Quality Tools

  1. Affinity diagram

  2. Relations diagram

  3. Tree diagram

  4. Matrix diagram

  5. Matrix data analysis

  6. Arrow diagram

  7. Process decision program chart (PDPC)

The Lean Practitioner Training Program is only available as an in-company programme of courses. The host company is responsible for the venue costs.

It can also be delivered for a Supplier Group – hosted by a ‘Parent’ customer organization.

Who should attend

The course was developed by Dr David Scrimshire (MD of TEC Transnational) specifically for aerospace, defence, automotive, motorsport and rail organizations - and their supply chains. The course is targeted at groups of individuals who are being earmarked as Lean Practitioners and future senior managers.

It is also relevant to existing team leaders wanting to update their Lean Enterprise skills and to aspiring individuals who have the potential for future development into SC21 Man Ex Practitioners/Lead Practitioners.

Deliverables & benefits

Individual benefits:

On completion of this Lean Practitioner Training Program participants will be able to:

  • Deploy lean enterprise tools and techniques in a practical manner

  • Analyse and reconfigure your workplace to create a more productive and efficient environment

  • Identify waste in all areas of your business and how to tackle it

  • Have a clear understanding of your anticipated work demand and the level of resource required to process it on time

  • Significantly improve the quality of your work output

  • Capture your current processes and create suitable documentation to ensure standardised work practices

  • Determine root cause of problems that affect your work and put in place solutions that permanently resolve the problem

  • Create visual management displays to improve communication and motivate staff

  • Design more efficient methods of processing our work to improve speed of delivery and reduce costs

Organization benefits:

Be confident in knowing that your selected personnel have all of the industry-specific Lean Enterprise skills expected by customers, and are able to provide the leadership and support to their colleagues.

  • Make real gains in greater efficiency and quality

  • Identify and minimise practices that waste money and time

  • Measure business improvements

  • Motivate all employees and encourage cross-organisation participation

  • Boost customer satisfaction and stakeholder confidence

  • Demonstrate people development and encourage the sharing of lean enterprise practices leading to better performance

  • Up-skill the participants in the use of modern lean tools and techniques

TEC’s expert tutors will guide participants through the Lean Principles and Tools and show you how to deliver the benefits in the workplace with hands-on exercises and projects.


Enquire about Lean Practitioner Training Program - Face to Face

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