Lean Six Sigma & Quality
Lean Foundations Workshop
A two-day workshop on Lean thinking.
2 daysFoundation7 modules
About this course
A two-day workshop on Lean thinking. You will separate value from waste, map current and future value streams, measure flow, eliminate waste, design pull and flow, and build quality in at the source. You will also plan a Kaizen event and learn how to sustain the gains.
What you'll learn
- Explain Lean principles and distinguish value-add vs. non–value-add work
- Create current- and future-state value stream maps to visualize flow
- Measure and interpret takt time, cycle time, lead time, WIP, and throughput
- Identify and reduce the eight wastes (muda), using 5 Whys and cause-and-effect
- Apply 5S, visual management, standard work, and basic Kanban/WIP limits
- Plan and facilitate a focused Kaizen/PDCA improvement effort and sustain results
Curriculum
7 modules
- Origins of Lean and the Toyota Production System
- Customer value vs. non–value-add work
- The eight wastes (muda) and waste-walk techniques
- Lean, Six Sigma, and Agile, where each fits
- Process mapping vs. value stream mapping (VSM)
- Current-state vs. future-state design
- Takt time, cycle time, lead time, WIP, and bottlenecks
- Introduction to Little’s Law and flow efficiency
- Gemba walks and structured observation
- Root cause analysis (5 Whys, fishbone)
- Quick wins, prioritization, and impact–effort grids
- Changeover basics (SMED-lite concepts)
- Batch size, flow, and line balancing
- Kanban signals and setting WIP limits
- Standard work and visual work instructions
- Level loading (heijunka) fundamentals
- Error-proofing (poka-yoke) and andon
- 5S and workplace organization
- Daily huddles and tiered escalation
- Visual controls and performance boards
- PDCA and A3 problem solving
- Planning and running a Kaizen event
- Control plans and sustaining gains
- Coaching behaviors and change adoption
- Selecting KPIs (lead time, throughput, FTQ, OEE overview)
- Baselines, dashboards, and review cadence
- Before/after storytelling and benefits tracking
- 30/60/90-day improvement roadmap
Who it's for
Operations, quality and process improvement staff in any industry.
Before you start
- No formal prerequisites
- Familiarity with your organization’s processes and metrics is helpful
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