Lean Manufacturing Training: 2 Days

Lean Manufacturing Training Course Lean Manufacturing Training
By Tang Yew Kit
Lean Manufacturing:

Lean Manufacturing: Waste Reduction & Productivity Improvements

“Provides clear focus on what tools to use, when to use them, and how to set sensible waste reduction measures in order to communicate gains made in the areas of focus.”

Tang Yew Kit

Certified Global Supply Chain Black Belt • Certified Success Motivation International • PSMB Certified Trainer
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Course Title:
Lean Manufacturing: Waste Reduction & Productivity Improvements
Training Category:
Manufacturing Operations
Target Audience:
Senior managers, direct reports, and union leaders, Department managers and supervisors, Key Process Owners, Implementation Team
2 Days
For In-house Training
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Delivery Methods
  • Language: English
  • PowerPoint Presentation
  • Group Discussion
  • Presentation Handouts
  • Indoor Activities
  • Participant Presentation
  • Case Studies
  • Certificate of Participation
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Course Introduction ›

Many businesses struggle with Waste Reduction. A clear understanding of what the tools are and how to use them is essential to the implementation of waste reduction. Education of the entire workforce is needed to sustain the gains made in Lean Manufacturing initiatives. The question is who in your organization is leading the change and what is the correct road map to use? Without a clear understanding of what waste reduction practices and concepts are, the implementation is doomed.

The Waste Reduction Overview course is used to bring an awareness and understanding to participants about the concepts and philosophies of Waste Reduction. This class will provide the group with a clear focus on what tools to use, when to use them, and how to set sensible waste reduction measures in order to communicate gains made in the areas of focus. The course will lead to an in-depth understanding on why Waste Reduction is so important in order to compete in the global economy and why many world class companies are racing to implementing the system.

Course Objectives ›

Upon completion of this 2-day Lean Manufacturing training program, participants should be able to:

  • Gain an understanding of the Waste Reduction Techniques and a methodology to incorporate changing requirements.
  • Demonstrate need for Leadership involvement
  • Understand the assessment, review and improvement process using "Lean" waste reduction techniques
  • Define leadership key roles and responsibilities during the transition from implementation mode to sustaining and improvement of all processes
  • Provide concepts understanding of the "Lean" approach to allow evaluating the technique as an effective tool for identifying and driving focused improvement teamwork
  • Understand how to identify the 7 main sources of waste and concepts to eliminate them

Course Outline ›



  • Be customer focused: Be on-time, responsive, flexible & fast
  • Simplify & standardize workflows
  • Manage capacity: increase process uptime, reduce setup times, find lost capacity
  • Eliminate waste: identify non-value adding activities, then modify, combine or eliminate those tasks
  • JIT: Just in Time concept


  • Key to identify types of wastes and variances in workplace
  • Project plan: How to eliminate and reduce wastes & variances in your workplace?
  • Value Analysis - identify Value-Added (VA), Least Value-Added (LVA) & Non-Value-Added (NVA) Activities


  • Mapping the process from incoming order to outgoing product: Define process goals, create the current state map, and establish process metrics
  • Using the current state map to identify potential improvements, conceive the future state
  • Create a macro-facility workflow to determine how to minimize high volume travel distances
  • Conduct a micro-process workflow to apply cellular concepts, identify & remove bottlenecks, move to pull manufacturing with kanbans
  • Production Levelling - Heijunka


  • Process Flow analysis
  • Therbligs analysis
  • Motion Chart / Man-Machine Analysis
  • Ergonomics Design / workplace


  • Improving Layouts - arranging process in a natural flow order, building in ergonomics in workstation, linking processes to minimize time & distance, moving equipment together to simulate a continuous process flow; putting internal customers & suppliers next to each other
  • Pull System & Kanban concepts - designing processes & scheduling based on pull system, rather than push system,
  • Calculating Kanban numbers for effective pull control
  • Comparison of different Kanban & when to use them


  • Use DFA/DFM to design quality
  • Conduct GR&Rs to ensure reliable measurement systems are in place
  • Employ SPC to help ensure processes are predictable & stable
  • Eliminate & reduce error through Poka Yoke


  • Use status display of performance for dashboard or balanced measures & COQ results
  • Total 5S concepts: Standardizing process
  • Visual controls such as sensory alerts indicate of something is out of place


  • Applying SMED concepts
  • Process analysis to identify internal & external tasks - setup lead time analysis


  • Enhancing & developing supplier-customer relationships
  • Improving quality & delivery in supplier process


  • Types of Maintenance - Reactive, Preventive, Predictive, Prevention
  • Understand machine / equipment efficiency - OEE calculation


  • Start with the people issues - management and staff
  • Focus on workplace organization, use value stream analysis & process workflow analysis to establish effective layouts
  • Use targeted Kaizen / TQM events to speed changes
  • Whole Supply Chain Management Concept - from scheduling, purchasing, process to inventory


  • How to overcome them effectively?

Contact us now ›

  • Course content customization
  • In-house training request
  • Available public program
  • Consultation services
  • Other inquiries
Contact Customer ServiceCall : +603-4270-3064, +6016-5488-336
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