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Lean Manufacturing Courses

The training was developed by Chris Turner - Lean Manufacturing Coach.

Listed below is information about our 3

lean manufacturing courses

Lean Manufacturing Courses

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Our online self-paced Lean Manufacturing training courses are designed to allow you to learn about the concepts, development and application of in an production area or manufacturing environment. Our training courses are structured based on the 10 Steps to become a Lean Enterprise training and implementation model that was designed and developed by Chris Turner – Lean Manufacturing Coach. You can get access to a free demonstration video of our online lean training system by signing up for a free membership account.

As you follow along with the 10 Step training and implementation model, we introduce you to three levels of lean manufacturing training, each specifically designed to meet your needs. As you go through each level you gain a deeper understanding of how to apply lean principles. These three levels are:

Level 1 – Lean Awareness in Manufacturing (Beginner)
Level 2 – Lean Practitioner in Manufacturing (Intermediate)
Level 3 – Lean Expert (Generic) (Advanced)

The training modules in each of these three levels are self-paced, which means they allow you to learn at your own speed. This makes it much easier to fit the course work into your busy schedule.

Each training level is designed to deliver the necessary information, and at the same time stay within your budget. All you need to start learning today is a computer with the latest version of Adobe Flash Player or HTML5 and an internet connection. With the Lean Certification Online training, there are no additional costs or out of pocket expenses such as the need to purchase reference books, time away from work, travel costs, etc. Each training module includes access to an instructional video for 12 months after purchase. Also included in the training materials is a course workbook and any support documents, these can be downloaded to your computer. We designed our system to be a virtual one-stop shop. Everything you need is included in each training package.

Our clients are individuals and organizations that want to learn about lean techniques to improve their administrative practices. We adhere to the principles defined in the Toyota Production System (TPS). Our self-paced lean training courses are based on these tried and tested principles that Toyota uses to identify and eliminate waste, improve quality, reduce costs and increase value for their customers.
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Lean Awareness in Manufacturing Training Package
Lean Awareness in Manufacturing Training Package
Purchase our Level 1 - Lean Awareness in Manufacturing training course. There are six training modules plus a Lean Glossary included in the course materials.
Price: $127.00

Level 1 – Lean Awareness in Manufacturing Training

Our introduction to the “10 Steps to become a Lean Enterprise” program starts with this training module called “Lean Awareness in Manufacturing.” This module is the foundation of the ‘10 Steps to become a Lean Enterprise’ training series. This training course is specifically designed for anyone that has limited or no prior knowledge of lean principles.

Lean Awareness in Manufacturing gives the participant a deeper understanding of the 10 Steps model and how it can be applied in a production area or manufacturing facility. Lean Certification Online training modules teach the same lean (or just-in-time) principles that are used in the Toyota Production System (TPS).

Level 1 – Lean Awareness in Manufacturing Course Objectives:

As a learner works through each training module, they will see a screen with an outline of the course objectives. These objectives are the steps a learner needs to fully understand and be able to apply to achieve the overall training goal for each course.

Upon completion of this course, you should be able to:

  1. Understand and define Lean principles.
  2. Understand the LCO LEAN model
  3. Define Customer Expectations.
  4. Define Value vs. Non-value.
  5. Describe the Ratio of Value vs. Non-value.
  6. Describe the Eight Wastes.
  7. Describe a Traditional vs. a Lean improvement.
  8. Describe the 10 Steps to become a Lean Enterprise.
  9. Describe the LCO ISEE Cycle.
  10. Describe the benefits of becoming a Lean Enterprise.

This training module covers the basic concepts of Lean principles. Participants that complete the Lean Awareness in Manufacturing training course do not receive a certificate, so there is no exam or pass score requirement.
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Lean Practitioner in Manufacturing Training Package
Lean Practitioner in Manufacturing Training Package
Purchase this package and get our Level 2 - Lean Practitioner in Manufacturing training course, plus the Level 1 - Lean Awareness in Manufacturing training course. This package includes a total of 28 training modules, which is an incredible value.
Price: $497.00

Level 2 – Lean Practitioner in Manufacturing Training:

Our intermediate level in the “10 Steps to become a Lean Enterprise” program is a thirteen part training course called “Lean Practitioner in Manufacturing.” This training course starts to build a framework (or structure) onto the solid foundation of lean concepts that was developed in the Lean Awareness in Manufacturing training module. This training package has instructional videos with a total run-time of 6.5 hours. The instruction and exercises included in this package are presented over a 5 days or 40 hours of on-site training.

The lean manufacturing courses teach the same just-in-time principles that were developed by Toyota and are still being used today in the Toyota Production System (TPS).

Lean Practitioner in Manufacturing course allows the participant to learn about the application and implementation of Lean Principles into a production area or manufacturing facility. The training follows the “10 Steps to become a Lean Enterprise” model to identify and define the activities involved in a successful lean implementation process. As a learner works through each of these thirteen training modules, they will increase their knowledge of lean principles and how they are applied.

Level 2 – Lean Practitioner in Manufacturing Course Objectives:

As a learner works through each training module, they will see a screen with an outline of the course objectives. These objectives are the steps a learner needs to fully understand and be able to apply to achieve the overall training goal for each course.

Step 1 – Strategy Deployment Part 1

  1. Explain the importance of becoming a Lean Enterprise
  2. Describe the difference between doing and living Lean.
  3. Describe the 3 key components of a Lean Enterprise.
  4. Describe the 5 cultural enablers of a Lean Enterprise.
  5. Describe how companies are using lean principles
  6. Describe how to become a Lean Enterprise
  7. Describe the 8 wastes.
  8. Complete a Lean exercise

Step 1 – Strategy Deployment Part 2

  1. Describe the 3 elements of manufacturing work.
  2. Describe the 3 elements of office work.
  3. Describe a traditional process improvements.
  4. Describe a lean process improvements.
  5. Describe the LCO LEAN Model.
  6. Complete a Lean exercise.

Step 1 – Strategy Deployment Part 3

  1. Describe Step 1 – Strategy Deployment.
  2. Describe the 9 levels of Strategy Deployment.
  3. Describe the Breakthrough Model.
  4. Describe the concept of True North.
  5. Describe the Deming Cycle (PDCA).
  6. Describe the ISEE Cycle.
  7. Describe combining the ISEE and PDCA Cycles.
  8. Complete a Lean exercise.

Step 2 – Value Stream Mapping Part 1

  1. Describe Step 2 – Value Stream Mapping.
  2. Describe the 4 steps of Value Stream Mapping.
  3. Describe a Product Family.
  4. Describe Current State Map.
  5. Describe a Future State Map.
  6. Describe a Value Stream Implementation Plan.
  7. Complete a Lean exercise.

Step 3 – Workplace Organization Part 1

  1. Describe Step 3 – Workplace Organization.
  2. Participate in the 30 second challenge.
  3. Describe the 1st S – Sort.
  4. Describe the 2nd S – Set in Order.
  5. Describe the 3rd S – Shine.
  6. Describe the 4th S – Standardize.
  7. Describe the 5th S – Sustain.
  8. Describe the purpose of Visual Management.
  9. Describe a 5S event.
  10. Complete a Lean exercise.

Step 2 – Workplace Organization Part 2

  1. Describe Step 3 – Workplace Organization.
  2. Describe the 5S levels of achievement.
  3. Describe the purpose of a 5S audit.
  4. Describe the process of performing a 5S Audit.
  5. Describe the presentation of the 5S Audit results.
  6. Complete a Lean exercise.

Step 4 – Improve Process Flow Part 1

  1. Describe Step 4 – Improve Process Flow
  2. Describe a functional facility layout.
  3. Describe a functional production layout.
  4. Describe how process location affects lead time.
  5. Describe the transition from a functional to a flow layout.
  6. Describe the ideal layout for a Lean Enterprise.
  7. Complete a Lean exercise.

Step 5 – Reduce Changeover Times Part 1

  1. Describe Step 5 – Reduce Changeover Times.
  2. Describe a traditional changeover.
  3. Understand the definition of a changeover.
  4. Describe the four elements of a changeover.
  5. Describe the four steps for reducing changeover times.
  6. Differentiate internal and external elements.
  7. Complete a Lean exercise.

Step 6 – Implement a Pull System Part 1

  1. Describe Step 6 – Implement a Pull System.
  2. Describe a batch and queue process.
  3. Describe a single piece flow process.
  4. Describe a kanban.
  5. Describe how to use kanban to link processes together.
  6. Describe how to use kanban to control production.
  7. Complete a Lean exercise.

Step 7 – Balanced Workload Part 1

  1. Describe Step 7 – Balanced Workload.
  2. Describe the two elements of production workload.
  3. Describe how to Identify a constraint or bottleneck.
  4. Describe how to perform a work content analysis.
  5. Describe how to balance the work content.
  6. Describe how to balance the workload scheduling.
  7. Complete a Lean exercise.

Step 8 – Standard Work Part 1

  1. Describe Step 8 – Standard Work.
  2. Describe the purpose of Standard Work documents.
  3. Describe a Standard Work Layout sheet.
  4. Describe a Standard Work Combination sheet.
  5. Describe the takt time formula.
  6. Describe the Standard Work Visual Display board.
  7. Complete a Lean exercise.

Step 9 – Continuous Process Improvement Part 1

  1. Describe Step 9 – Continuous Process Improvement.
  2. Describe the 8 step problem-solving model.
  3. Describe an A3 template.
  4. Describe the 5 Why’s method.
  5. Describe the concept of Kaizen.
  6. Describe the purpose of a Process Improvement Team.
  7. Describe a Rapid Improvement Event (RIE).
  8. Describe some continuous improvement traps.
  9. Complete a Lean exercise.

Step 10 – Lean Supply Chain Part 1

  1. Describe Step 10 – Lean Supply Chain.
  2. Describe a supply chain concept.
  3. Describe the importance of supplier relationships.
  4. Describe the importance of customer relationships.
  5. Describe what influences customer ordering behavior.
  6. Complete a Lean exercise.

These training modules cover the basic application of lean principles into any workplace or manufacturing facility. The learner will be required to take an exam and achieve an 80% pass score to receive a Lean Practitioner Certificate of Achievement.
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Lean Expert in Manufacturing Training Package
Lean Expert in Manufacturing Training Package
Purchase this package and get our Level 3 - Lean Expert in Manufacturing training package, which includes the Level 3 - Lean Expert training course, plus the Level 2 - Lean Practitioner in Manufacturing and Level 1 - Lean Awareness in Manufacturing training courses. This package includes a total of 55 training modules, which is an incredible value.
Price: $1,397.00

Level 3 – Lean Expert Training:

Lean Expert allows the learner to develop an advanced level of knowledge and understanding about the implementation and integration of Lean Principles into any organization. The Lean Expert training course was designed and developed as a generic package. Why did we do this? Well, its because a person that successfully achieves a Lean Expert skill level must be capable of applying their lean knowledge into any type of business environment. For example, they should be able to work with and implement lean principles into a manufacturing, service or healthcare organization.

The learner is taken through a systematic process using the “10 Steps to become a Lean Enterprise” model to help focus and prioritize all the implementation and integration activities. Lean Certification Online training modules teach the same principles that are used in the Toyota Production System (TPS).

As a learner completes each of the twenty seven training modules, they will increase their knowledge and develop the ability to apply the “10 Steps to become a Lean Enterprise” model into any business environment. The Lean Expert Course Objectives allow you to view the training modules in each of the ten steps. Click on any of the links to see more details about a specific step on this page.

Level 3 – Lean Expert Course Objectives:

As a learner works through each training module, they will see a screen with an outline of the course objectives. These objectives are the steps a learner needs to fully understand and be able to apply to achieve the overall training goal for each course.

Step 1 Strategy Deployment.
Step 2 Value Stream Mapping.
Step 3 Workplace Organization.
Step 4 Process Flow.
Step 5 Reduce Changeover Times.
Step 6 Pull System.
Step 7 Balanced Workload.
Step 8 Standard Work.
Step 9 Continuous Improvement.
Step 10 Lean Supply Chain.

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Step 1: Strategy Deployment – Part 1 of 4:
  1. Understand the use of the importance of the ISEE cycle.
  2. Participate in a Strategic development process.
  3. Develop and implement Breakthrough Objectives (BTO).
  4. Develop and implement Annual Improvement Priorities (AIP).
  5. Plan improvements over the next 12 months.
  6. Develop and implement Target Improvements (TI).
  7. Develop and implement Tasks.

Step 1: Strategy Deployment – Part 2 of 4:

  1. Understand the Breakthrough Model.
  2. Understand the application an Enterprise PDCA.
  3. Understand the importance of establishing a feedback loop.
  4. Understand the purpose of an executive review.
  5. Understand common problems during SD implementation.

Step 1: Strategy Deployment – Part 3 of 4:

  1. Understand the application of Strategy Deployment (SD).
  2. Understand the 3 levels of the SD Application.
  3. Determine key focus areas for improvement.
  4. Understand the tools of Strategy Deployment.
  5. Understand the Strategy Deployment planning and scheduling process.

Step 1: Strategy Deployment – Part 4 of 4:

  1. Understand Quality, Cost and Delivery (QCD).
  2. Understand the five benefits of QCD.
  3. Understand the importance of QCD.
  4. Understand the seven key QCD metrics.
  5. Understand the five-step QCD process.
  6. Understand how to monitor process performance using QCD.
  7. Understand the QCD feedback process.

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Step 2: Value Stream Mapping – Part 1 of 3:

  1. Understand the 4 steps of Value Stream Mapping.
  2. Understand the purpose of Value Stream Mapping.
  3. Understand the Data Collection Process.
  4. Understand Step 1 of 4, identify Product Families.
  5. Understand Step 2 of 4, draw a Current State Map.
  6. Identify Opportunities for Improvements.

Step 2: Value Stream Mapping – Part 2 of 3:

  1. Understand the Value Stream Mapping data collection process.
  2. Understand how to draw a Current State Map.

Step 2: Value Stream Mapping – Part 3 of 3:

  1. Understand how to draw a Future State Map.
  2. Understand how to develop a VSM Implementation Plan.

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Step 3: Workplace Organization – Part 1 of 4:

  1. Understand the purpose of 5S.
  2. Understand each of the 5S activities.
  3. Understand the term “cross-functional team”.
  4. Understand each of the 5S tools.

Step 3: Workplace Organization – Part 2 of 4:

  1. Understand how to apply the 5S tools.
  2. Understand how to convert the 5S concepts into standard practices.
  3. Understand how to sustain all 5S improvements in the workplace.

Step 3: Workplace Organization – Part 3 of 4:

  1. Understand the definition of visual management.
  2. Understand the five levels of visual control.

Step 3: Workplace Organization – Part 4 of 4:

  1. Understand the visual management objectives.
  2. Understand the three I’s of visual management.
  3. Understand the visual management improvement cycle.
  4. Understand how to apply visual management techniques in the workplace.

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Step 4: Improve Product Flow – Part 1 of 2:

  1. Define process flow.
  2. Understand the reason for lead-time
  3. Apply Little’s Law to see how inventory affects lead-time.
  4. Identify where to begin to improve process flow.
  5. Understand how to draw a travel diagram.
  6. Understand the different types of workstation design.
  7. Understand how fixtures improve process flow.
  8. Understand how ergonomics affects workstation design.

Step 4: Improve Product Flow – Part 2 of 2:

  1. Understand material replenishment.
  2. Understand the purpose of part presentation.
  3. Understand the different methods for delivering parts and materials to the work area.
  4. Understand the use of line side markets.
  5. Understand the principles of kitting for inventory and production control.

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Step 5: Reduce Changeover Times – Part 1 of 5:

  1. Understand the definition of changeover time.
  2. Understand the elements of a changeover.
  3. Understand the development of traditional changeovers.
  4. Understand the concept of an economic order quantity.

Step 5: Reduce Changeover Times – Part 2 of 5:

  1. Understand the steps to improve changeover times.
  2. Understand how to document and record changeover activities.
  3. Understand how to separate changeover activities into internal and external
    elements.

Step 5: Reduce Changeover Times – Part 3 of 5:

  1. Understand how to convert internal elements into external elements.
  2. Understand the importance of developing instruction sheets.

Step 5: Reduce Changeover Times – Part 4 of 5:

  1. Understand how to streamline all aspects of the changeover operation.
  2. Understand function standardization.
  3. Understand the purpose of using intermediary jigs.
  4. Understand the use of parallel operations.

Step 5: Reduce Changeover Times – Part 5 of 5:

  1. Understand Step 4 – Streamline all aspects of the changeover operation…continued from Part 4 of 5.
  2. Understand the application of functional clamping.
  3. Understand the need to eliminate adjustments.
  4. Understand the use of kitting to reduce changeover times.
  5. Understand the purpose of developing changeover instructions.

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Step 6: Implement a Pull System – Part 1 of 1:

  1. Understand the resource, batch size & inventory dilemmas.
  2. Understand a batch and queue process.
  3. Understand a single piece flow process.
  4. Understand the concept of a pull system.
  5. Understand how to link processes using kanban.
  6. Understand the purpose for using kanban.
  7. Recognize 3 types of kanban.
  8. Understand material replenishment using a pull system.

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Step 7: Balance the Workload – Part 1 of 2:

  1. Understand the principles of a balanced workload.
  2. Identify the two key focus areas for balancing the workload.
  3. Understand the data collection process.
  4. Understand how to analyze the data to balance the workload.
  5. Understand how to calculate takt time and apply it.
  6. Understand the formula for balancing the workload between operations.

Step 7: Balance the Workload – Part 2 of 2:

  1. Understand the heijunka load leveling process.
  2. Understand how heijunka improves the flow of products.
  3. Understand how to to apply heijunka to single or mixed model production.
  4. Understand how to implement load-leveling techniques.

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Step 8: Develop Standard Work – Part 1 of 1:

  1. Understand the process of standardization.
  2. Understand how culture affects standardization.
  3. Understand the importance of standard work.
  4. Identify the types of standard work tools.
  5. Explain how standard work documents are used.

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Step 9: Continuous Process Improvement (CPI) – Part 1 of 3:

  1. Define Continuous Improvement.
  2. Understand Problem Solving.
  3. Understand the how problem solving has evolved.
  4. Identify the different types of problems.
  5. Understand Management’s role in problem solving.
  6. Define a process.
  7. Understand the 8 Step Problem Solving process.
  8. Understand the A3 template and how to use it.
  9. Understand the problem solving tools.
  10. Understand the purpose of an A3 storyboard.

Step 9: Continuous Process Improvement (CPI) – Part 2 of 3:

  1. Identify the key problem solving tools.
  2. Understand the application of brainstorming.
  3. Understand the application of affinity diagrams.
  4. Understand the application of an impact-effort matrix
  5. Understand the application of flow charts.
  6. Understand the application of a data sheet.
  7. Understand the application of check sheets.
  8. Understand the application of run charts.
  9. Understand the application of histograms.
  10. Understand the application of pareto charts.
  11. Understand the application of cause and effect diagrams.
  12. Understand the application of scatter diagrams.

Step 9: Continuous Process Improvement (CPI) – Part 3 of 3:

  1. Understand the concept of kaizen.
  2. Understand the RIE procedure.
  3. Understand the purpose of high and low level events.
  4. Understand how to choose RIE team members.
  5. Understand RIE procedure activities.
  6. Understand how to create a RIE agenda.

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Step 10: Lean Supply Chain – Part 1 of 1:
  1. Understand the importance of a Lean Supply Chain.
  2. Define a Supply Chain.
  3. Understand how to develop a competitive advantage.
  4. Understand the difference between a “make to order” and “make to stock” process.
  5. Understand the purpose of a “tradeoff curve”.
  6. Understand the bullwhip effect.
  7. Understand the causes of the bullwhip effect.
  8. Understand Vendor Managed Inventory(VMI).

These lean manufacturing courses cover the advanced application and integration of Lean principles into any business model.

The learner will be required to take an exam and achieve an 80% pass score to receive a Lean Expert Certificate of Achievement. The content goes here.

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