Lean manufacturing

Lean thinking is a widely adopted customer-facing improvement approach that can greatly simplify processes and improve performance in both manufacturing and service organizations. Effectively applying Lean principles and tools can significantly improve productivity and reduce waste and associated costs. At the same time, these tools drive an improvement in customer service and satisfaction levels.

This intensive two-day program gives participants a practical, hands-on, learning-by-doing experience applying Lean methodologies in a simulated environment. Participants will develop basic skills in how to use Lean tools to achieve continuous improvement.


Introduction and History of Lean

  • Definition of Lean
  • The History of Lean
  • The Benefits of Lean
  • Defining Value
  • Key ideas supporting Lean Process Improvement: value, waste, variation, complexity, continuous improvement
  • The concept of Flow in a Process
  • The Concept and Impact of Pull

Waste Elimination

  • Introduction to the Seven Wastes
  • Muda, Muri, and Mura
  • Recognising Waste at the Workplace
  • Documenting Wasteful Activities
  • Developing a Lean Mind-set

Lean Techniques

  • 5S
  • 5W-2H
  • 5 Why Analysis
  • Value Stream Mapping
  • Pareto Diagrams
  • Cause-and-Effect Diagrams
  • SIPOC diagrams
  • TAKT Time
  • Flow Rate:  Constraint (Bottleneck) Management
  • Kanban
  • PDCA
  • Genchi  Genbutsu
  • Single Piece Flow & Batch Reduction
  • Changeover Reduction
  • Work Cell Design
  • Workload Balancing & Demand Levelling
  • Standard Work
  • Visual Management
  • Kaizen

 Implementing and Sustaining Lean

  • Obtaining “Buy-in”
  • The Starting Point
  • Transferring Knowledge
  • Leader Standard Work (LSW)
  • Leader Task Boards
  • A3 Coaching
  • Process Performance Boards
  • How Meetings can be used in a Lean Environment
  • Sustaining Lean Efforts

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Contact Us


  +27 82 443 5866 - Harold

  +27 82 873 9996 - Carol

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