Mastering Lean Manufacturing: Achieve Operational Excellence and Future-Proof Your Career
You’re not behind. But you’re not ahead either. In today’s high-pressure manufacturing environment, incremental improvements don’t cut it. You need transformation. Fast. The floor is changing-automation, global competition, rising costs-and if you’re not leading the charge on efficiency, someone else is. Waste is invisible until you know how to see it. And once you do, it's everywhere. Excess inventory. Unplanned downtime. Overproduction. Poor workflow. These aren't just operational hiccups-they're profit leaks, career stagnation in disguise, and vulnerabilities that put your job, your team, and your reputation at risk. Mastering Lean Manufacturing: Achieve Operational Excellence and Future-Proof Your Career is the structured, battle-tested pathway from cost-focused technician to value-driven leader. This isn’t theory. It’s the exact system used by top performers to deliver 20%+ efficiency gains, eliminate millions in waste, and earn recognition they didn’t have before. Take Sarah Kim, a production supervisor in Ohio. After applying the process mapping technique from this course, she identified a bottleneck in her cell that reduced output by 35%. She led a team intervention that restored flow, cut lead time in half, and presented the results to senior leadership-earning a promotion and a spot on the continuous improvement council. This course is engineered for professionals who need real results, fast. From your first day, you’ll move from confusion to clarity. You'll build a board-ready action plan, grounded in proven lean principles, that directly impacts your KPIs-productivity, quality, cost, and safety. You'll go from overwhelmed to in control. From reactive to strategic. From overlooked to indispensable. And you’ll do it in under 30 days-with a complete implementation roadmap tailored to your facility. Here’s how this course is structured to help you get there.Course Format & Delivery Details Learn On Your Terms. Succeed On Your Timeline.
This program is designed for real professionals with real schedules. You get immediate online access to a fully self-paced curriculum. No fixed start dates. No missed classes. No pressure to keep up. You progress at your own speed, on your own time. Most learners complete the core material in 4 to 6 weeks. But you can see tangible results in as little as 10 days. Implement one tool, like 5S or Value Stream Mapping, and you’ll already be uncovering waste others have missed. Access is 24/7 and fully mobile-friendly. Whether you're planning your next kaizen event on a tablet during a shift change, or reviewing SMED frameworks from your phone before a morning huddle-you’re always in control. Unlimited Access. Lifetime Updates.
You’re not buying a one-time course. You’re investing in a permanently evolving toolkit. This includes lifetime access to all materials, with ongoing updates rolled in at no extra cost. As lean practices evolve, so does your knowledge-automatically. Instructor Support When You Need It
You’re not alone. You’ll receive direct guidance from certified lean practitioners with 15+ years of operational experience. Submit questions through our secure portal and receive detailed, role-specific responses-within 48 business hours. Certificate of Completion: A Career-Accelerating Credential
Upon finishing the course, you’ll earn a professionally issued Certificate of Completion from The Art of Service. This globally recognised credential is trusted by Fortune 500 manufacturers, engineering firms, and supply chain leaders. It validates your expertise and signals strategic initiative to employers and hiring committees. LinkedIn profiles featuring this certification see up to 37% more visibility in operations-related searches. This isn’t just paperwork-it’s proof you deliver results. Transparent, Upfront Pricing. Zero Risk.
No hidden fees. No surprise subscriptions. No fine print. The price covers full curriculum access, all tools, templates, instructor support, and your official certificate-forever. We accept Visa, Mastercard, and PayPal-securely processed with bank-level encryption. Your data is protected at every step. 100% Money-Back Guarantee
If you complete the first three modules and don’t believe this course will help you reduce waste, lead improvement initiatives, or strengthen your position at work-we’ll refund every dollar. No questions, no hassle. Your risk is completely reversed. You’re Covered From Your First Click
After enrollment, you’ll receive a confirmation email confirming your registration. Once your course materials are prepared and quality-checked, your access details will be sent in a separate message. This ensures you receive a flawless, optimised learning experience from day one. “Will This Work For Me?” - We’ve Got You Covered.
It works whether you’re in automotive, pharmaceuticals, aerospace, food processing, or discrete manufacturing. Whether you're an engineer, operations manager, plant supervisor, or continuous improvement coordinator-the frameworks here are scalable, modular, and engineered for real plants, real constraints, and real people. This works even if: - You’re new to lean and feel overwhelmed by jargon
- Your leadership is resistant to change
- Your team is running at capacity with no slack
- You’ve tried kaizen before and it fizzled out
We give you the communication scripts, stakeholder alignment tactics, and pilot prioritisation models that turn resistance into momentum. This is lean that sticks-not just survives. You’re backed by a decade of proven delivery. Over 14,000 professionals have used this system to lead successful rollouts, earn promotions, and future-proof their skills against automation and restructuring. Your investment is safe. Your growth is guaranteed. Your next career leap starts here.
Module 1: Foundations of Lean Thinking - The history and evolution of lean manufacturing
- Understanding the Toyota Production System DNA
- Core lean principles: Value, flow, pull, perfection
- Defining waste: The 8 forms of muda
- Origins of overproduction, waiting, transportation, over-processing
- Recognising defects, inventory, motion, and underutilised talent
- Lean vs Six Sigma: Complementary or conflicting?
- Role of leadership in fostering a lean culture
- Common misconceptions about lean manufacturing
- Building the business case for lean in your organisation
Module 2: Value Stream Analysis and Mapping - Identifying customer-defined value
- Differentiating value-added from non-value-added activities
- Selecting the right process for mapping
- Collecting accurate process data: Cycle times, wait times, downtime
- Constructing a current state value stream map
- Analysing takt time and production levelling
- Drawing information and material flows
- Calculating lead time, process time, and value-added ratio
- Identifying bottlenecks and constraint points
- Creating a future state map with flow and pull
- Prioritising improvement opportunities using VSM insights
- Validating assumptions with shop floor observations
- Presenting VSM findings to stakeholders
- Using digital templates to scale mapping across multiple lines
- Integrating VSM with continuous improvement systems
Module 3: 5S Workplace Organisation - Understanding Sort, Set in Order, Shine, Standardise, Sustain
- Defining red tagging and inventory rationalisation
- Creating visual workplaces with shadow boards and labels
- Designing efficient tool and material locations
- Implementing cleaning as inspection
- Documenting standards with photo-based checklists
- Developing daily, weekly, monthly 5S routines
- Conducting 5S audits and scoring systems
- Engaging teams in ownership and accountability
- Using 5S to reduce search time and errors
- Linking 5S to safety and quality performance
- Scaling 5S across departments and facilities
- Measuring before-and-after results: Floor space, time savings
- Overcoming resistance to workplace changes
- Automating reminders and audit tracking
Module 4: Standardised Work and Visual Management - Defining standardised work as a foundation for improvement
- Creating standard operating procedures with clear visual cues
- Developing work combination charts and sequence sheets
- Using cycle time, takt time, and work-in-progress alignment
- Designing process control boards
- Implementing Andon systems for real-time issue escalation
- Creating performance dashboards with OEE, yield, downtime
- Establishing visual controls for inventory and kanban
- Using colour coding for status, safety, and routing
- Training teams on visual discipline and compliance
- Linking standards to onboarding and cross-training
- Using visual management to reduce supervisor walkarounds
- Ensuring standards evolve with process changes
- Balancing flexibility with consistency
- Measuring adherence and impact on throughput
Module 5: Kaizen and Continuous Improvement - Understanding the philosophy of kaizen vs breakthrough improvement
- Running effective daily kaizen huddles
- Training team members to identify improvement ideas
- Implementing suggestion systems with follow-up discipline
- Conducting rapid improvement events (RIEs)
- Planning a kaizen week: Scope, team, schedule
- Facilitation techniques for cross-functional teams
- Using PDCA cycles within improvement events
- Implementing changes in real time with minimal downtime
- Documenting results and handover to operations
- Tracking kaizen impact on cost, quality, safety
- Recognising and rewarding contributor engagement
- Building a culture where everyone improves everything
- Linking kaizen to performance metrics and goals
- Sustaining momentum beyond the event
Module 6: Just-In-Time (JIT) and Pull Systems - Principles of Just-In-Time production
- Differences between push and pull systems
- Designing kanban systems: Card, bin, electronic
- Calculating kanban quantities and replenishment triggers
- Implementing supermarket pull systems
- Managing mixed-model production with JIT
- Reducing batch sizes and changeover times
- Aligning JIT with supplier delivery schedules
- Handling demand fluctuations in pull systems
- Applying JIT principles beyond manufacturing
- Overcoming inventory dependency culture
- Measuring JIT success: Inventory turns, stockouts, fill rates
- Integrating JIT with ERP and MRP systems
- Using visual signals to manage flow
- Avoiding common JIT implementation pitfalls
Module 7: Total Productive Maintenance (TPM) - Principles of operator-led maintenance
- Defining the 8 pillars of TPM
- Calculating and improving Overall Equipment Effectiveness (OEE)
- Measuring availability, performance, quality losses
- Implementing autonomous maintenance routines
- Developing maintenance standard work
- Conducting root cause analysis on equipment failures
- Reducing unplanned downtime using predictive techniques
- Creating equipment history logs and repair tracking
- Training operators on basic care and inspection
- Establishing cross-functional PM teams
- Using FMEA to anticipate failure modes
- Linking TPM to safety and environmental standards
- Tracking MTBF and MTTR trends
- Reporting TPM progress to leadership
Module 8: SMED – Single-Minute Exchange of Dies - Understanding internal vs external setup activities
- Mapping the current changeover process
- Converting internal steps to external preparation
- Standardising tools and attachments
- Implementing quick-connect utilities (air, power, data)
- Using pre-staged carts and kits
- Training teams on standardised changeover sequences
- Reducing human error with checklist enforcement
- Measuring setup time reduction and capacity gain
- Scaling SMED across similar machines and lines
- Integrating SMED with production scheduling
- Reducing minimum economic batch size
- Creating visual setup guides and instructional aids
- Engaging maintenance and engineering support
- Tracking financial impact: Throughput, inventory, responsiveness
Module 9: Lean Tools for Quality and Problem Solving - Integrating quality into lean systems
- Using Poka-Yoke for mistake-proofing
- Designing fail-safe mechanisms and sensors
- Applying the 5 Whys for root cause discovery
- Constructing fishbone (Ishikawa) diagrams
- Running effective problem-solving workshops
- Implementing A3 thinking for structured reporting
- Using Pareto analysis to prioritise defects
- Mapping defect flow with spaghetti diagrams
- Reducing rework and scrap through process control
- Linking quality metrics to operator incentives
- Creating standard response protocols for non-conformances
- Documenting lessons learned in a knowledge repository
- Using control charts for process stability
- Preventing recurrence through system changes
Module 10: Leading Lean Transformation - Diagnosing organisational readiness for change
- Building a lean vision aligned with business goals
- Creating a multi-year rollout roadmap
- Establishing a Lean Steering Committee
- Defining roles: Lean champions, facilitators, sponsors
- Developing a lean communication strategy
- Running pilot programs to demonstrate quick wins
- Measuring transformation progress with KPIs
- Using balanced scorecards for holistic tracking
- Scaling success from one line to the enterprise
- Managing resistance with empathy and data
- Developing internal coaching capability
- Integrating lean with digital transformation
- Aligning performance management with lean behaviours
- Institutionalising lean through policy and structure
Module 11: Lean in Supply Chain and Logistics - Extending lean principles beyond the factory floor
- Mapping end-to-end supply chain value streams
- Applying JIT to inbound and outbound logistics
- Designing milk-run delivery systems
- Reducing lead time in material handling
- Improving warehouse layout and flow
- Implementing cross-docking and flow-through operations
- Using kanban with suppliers and vendors
- Managing consignment and vendor-managed inventory
- Reducing transit damage and handling waste
- Integrating lean with ERP and WMS platforms
- Collaborating with logistics partners on improvement
- Measuring logistics performance: On-time delivery, fill rate
- Using data to negotiate better contracts
- Creating visibility across the extended enterprise
Module 12: Advanced Lean Analytics and Metrics - Selecting the right metrics for your goals
- Differentiating lagging vs leading indicators
- Calculating OEE, TEEP, and utilisation
- Tracking cycle time, takt time, and throughput
- Measuring first-pass yield and rework rates
- Using downtime codes for root cause analysis
- Building digital dashboards for real-time insight
- Setting performance targets and stretch goals
- Avoiding metric gaming and misalignment
- Linking metrics to daily management reviews
- Using data to justify improvement investments
- Reporting progress to executives and boards
- Creating scorecards for departments and teams
- Ensuring data accuracy and consistency
- Using simulation to forecast improvement impact
Module 13: Integrating Lean with Digital Technologies - Understanding Industry 4.0 and its relationship to lean
- Using IoT sensors for real-time monitoring
- Applying lean principles to automation projects
- Ensuring technology supports flow, not complexity
- Using digital twins for process simulation
- Implementing paperless workflows and mobile reporting
- Automating data collection for VSM and OEE
- Integrating lean with MES and SCADA systems
- Using AI for predictive maintenance and anomaly detection
- Reducing digital waste: redundant systems, poor interfaces
- Creating lean UX for operator-facing software
- Training teams on new digital tools without disruption
- Scaling improvement insights across global sites
- Measuring ROI of digital lean initiatives
- Future-proofing your skills in smart manufacturing
Module 14: Personal Lean Leadership Development - Assessing your current lean knowledge and gaps
- Defining your personal improvement mission
- Developing a personal roadmap for mastery
- Building confidence in leading change
- Practising lean communication and active listening
- Giving feedback that drives improvement
- Using coaching questions to unlock team potential
- Managing up: Influencing without authority
- Creating your personal brand as a continuous improver
- Documenting achievements for performance reviews
- Preparing for promotion into operations leadership
- Expanding your network with lean professionals
- Presenting your work to senior executives
- Using storytelling to make data compelling
- Staying current with evolving best practices
Module 15: Real-World Application and Capstone Project - Choosing a high-impact project in your current role
- Defining scope, objectives, and success criteria
- Gaining stakeholder buy-in and alignment
- Conducting a baseline assessment
- Applying lean tools: VSM, 5S, SMED, Kaizen
- Leading a cross-functional team through implementation
- Tracking financial and operational outcomes
- Documenting lessons learned and challenges
- Creating a sustainability plan
- Developing a board-ready presentation
- Measuring ROI and payback period
- Submitting your project for review
- Receiving expert feedback and recommendations
- Revising and finalising your capstone
- Adding your project to your professional portfolio
Module 16: Certification, Career Advancement & Next Steps - Preparing for your Certificate of Completion submission
- Understanding the assessment criteria from The Art of Service
- Formatting your capstone project for professional review
- Submitting your work through the certification portal
- Receiving your verified Certificate of Completion
- Adding the credential to your CV, LinkedIn, and résumé
- Drafting achievement statements for performance reviews
- Breaking into elite operations roles with lean differentiation
- Negotiating salary based on certified expertise
- Applying for roles: Continuous Improvement Manager, Lean Engineer, Operations Director
- Transitioning from technical to strategic leadership
- Accessing alumni resources and job boards
- Joining lean professional networks and associations
- Planning your next learning milestone
- Lifetime access: Updating your skills as lean evolves
- The history and evolution of lean manufacturing
- Understanding the Toyota Production System DNA
- Core lean principles: Value, flow, pull, perfection
- Defining waste: The 8 forms of muda
- Origins of overproduction, waiting, transportation, over-processing
- Recognising defects, inventory, motion, and underutilised talent
- Lean vs Six Sigma: Complementary or conflicting?
- Role of leadership in fostering a lean culture
- Common misconceptions about lean manufacturing
- Building the business case for lean in your organisation
Module 2: Value Stream Analysis and Mapping - Identifying customer-defined value
- Differentiating value-added from non-value-added activities
- Selecting the right process for mapping
- Collecting accurate process data: Cycle times, wait times, downtime
- Constructing a current state value stream map
- Analysing takt time and production levelling
- Drawing information and material flows
- Calculating lead time, process time, and value-added ratio
- Identifying bottlenecks and constraint points
- Creating a future state map with flow and pull
- Prioritising improvement opportunities using VSM insights
- Validating assumptions with shop floor observations
- Presenting VSM findings to stakeholders
- Using digital templates to scale mapping across multiple lines
- Integrating VSM with continuous improvement systems
Module 3: 5S Workplace Organisation - Understanding Sort, Set in Order, Shine, Standardise, Sustain
- Defining red tagging and inventory rationalisation
- Creating visual workplaces with shadow boards and labels
- Designing efficient tool and material locations
- Implementing cleaning as inspection
- Documenting standards with photo-based checklists
- Developing daily, weekly, monthly 5S routines
- Conducting 5S audits and scoring systems
- Engaging teams in ownership and accountability
- Using 5S to reduce search time and errors
- Linking 5S to safety and quality performance
- Scaling 5S across departments and facilities
- Measuring before-and-after results: Floor space, time savings
- Overcoming resistance to workplace changes
- Automating reminders and audit tracking
Module 4: Standardised Work and Visual Management - Defining standardised work as a foundation for improvement
- Creating standard operating procedures with clear visual cues
- Developing work combination charts and sequence sheets
- Using cycle time, takt time, and work-in-progress alignment
- Designing process control boards
- Implementing Andon systems for real-time issue escalation
- Creating performance dashboards with OEE, yield, downtime
- Establishing visual controls for inventory and kanban
- Using colour coding for status, safety, and routing
- Training teams on visual discipline and compliance
- Linking standards to onboarding and cross-training
- Using visual management to reduce supervisor walkarounds
- Ensuring standards evolve with process changes
- Balancing flexibility with consistency
- Measuring adherence and impact on throughput
Module 5: Kaizen and Continuous Improvement - Understanding the philosophy of kaizen vs breakthrough improvement
- Running effective daily kaizen huddles
- Training team members to identify improvement ideas
- Implementing suggestion systems with follow-up discipline
- Conducting rapid improvement events (RIEs)
- Planning a kaizen week: Scope, team, schedule
- Facilitation techniques for cross-functional teams
- Using PDCA cycles within improvement events
- Implementing changes in real time with minimal downtime
- Documenting results and handover to operations
- Tracking kaizen impact on cost, quality, safety
- Recognising and rewarding contributor engagement
- Building a culture where everyone improves everything
- Linking kaizen to performance metrics and goals
- Sustaining momentum beyond the event
Module 6: Just-In-Time (JIT) and Pull Systems - Principles of Just-In-Time production
- Differences between push and pull systems
- Designing kanban systems: Card, bin, electronic
- Calculating kanban quantities and replenishment triggers
- Implementing supermarket pull systems
- Managing mixed-model production with JIT
- Reducing batch sizes and changeover times
- Aligning JIT with supplier delivery schedules
- Handling demand fluctuations in pull systems
- Applying JIT principles beyond manufacturing
- Overcoming inventory dependency culture
- Measuring JIT success: Inventory turns, stockouts, fill rates
- Integrating JIT with ERP and MRP systems
- Using visual signals to manage flow
- Avoiding common JIT implementation pitfalls
Module 7: Total Productive Maintenance (TPM) - Principles of operator-led maintenance
- Defining the 8 pillars of TPM
- Calculating and improving Overall Equipment Effectiveness (OEE)
- Measuring availability, performance, quality losses
- Implementing autonomous maintenance routines
- Developing maintenance standard work
- Conducting root cause analysis on equipment failures
- Reducing unplanned downtime using predictive techniques
- Creating equipment history logs and repair tracking
- Training operators on basic care and inspection
- Establishing cross-functional PM teams
- Using FMEA to anticipate failure modes
- Linking TPM to safety and environmental standards
- Tracking MTBF and MTTR trends
- Reporting TPM progress to leadership
Module 8: SMED – Single-Minute Exchange of Dies - Understanding internal vs external setup activities
- Mapping the current changeover process
- Converting internal steps to external preparation
- Standardising tools and attachments
- Implementing quick-connect utilities (air, power, data)
- Using pre-staged carts and kits
- Training teams on standardised changeover sequences
- Reducing human error with checklist enforcement
- Measuring setup time reduction and capacity gain
- Scaling SMED across similar machines and lines
- Integrating SMED with production scheduling
- Reducing minimum economic batch size
- Creating visual setup guides and instructional aids
- Engaging maintenance and engineering support
- Tracking financial impact: Throughput, inventory, responsiveness
Module 9: Lean Tools for Quality and Problem Solving - Integrating quality into lean systems
- Using Poka-Yoke for mistake-proofing
- Designing fail-safe mechanisms and sensors
- Applying the 5 Whys for root cause discovery
- Constructing fishbone (Ishikawa) diagrams
- Running effective problem-solving workshops
- Implementing A3 thinking for structured reporting
- Using Pareto analysis to prioritise defects
- Mapping defect flow with spaghetti diagrams
- Reducing rework and scrap through process control
- Linking quality metrics to operator incentives
- Creating standard response protocols for non-conformances
- Documenting lessons learned in a knowledge repository
- Using control charts for process stability
- Preventing recurrence through system changes
Module 10: Leading Lean Transformation - Diagnosing organisational readiness for change
- Building a lean vision aligned with business goals
- Creating a multi-year rollout roadmap
- Establishing a Lean Steering Committee
- Defining roles: Lean champions, facilitators, sponsors
- Developing a lean communication strategy
- Running pilot programs to demonstrate quick wins
- Measuring transformation progress with KPIs
- Using balanced scorecards for holistic tracking
- Scaling success from one line to the enterprise
- Managing resistance with empathy and data
- Developing internal coaching capability
- Integrating lean with digital transformation
- Aligning performance management with lean behaviours
- Institutionalising lean through policy and structure
Module 11: Lean in Supply Chain and Logistics - Extending lean principles beyond the factory floor
- Mapping end-to-end supply chain value streams
- Applying JIT to inbound and outbound logistics
- Designing milk-run delivery systems
- Reducing lead time in material handling
- Improving warehouse layout and flow
- Implementing cross-docking and flow-through operations
- Using kanban with suppliers and vendors
- Managing consignment and vendor-managed inventory
- Reducing transit damage and handling waste
- Integrating lean with ERP and WMS platforms
- Collaborating with logistics partners on improvement
- Measuring logistics performance: On-time delivery, fill rate
- Using data to negotiate better contracts
- Creating visibility across the extended enterprise
Module 12: Advanced Lean Analytics and Metrics - Selecting the right metrics for your goals
- Differentiating lagging vs leading indicators
- Calculating OEE, TEEP, and utilisation
- Tracking cycle time, takt time, and throughput
- Measuring first-pass yield and rework rates
- Using downtime codes for root cause analysis
- Building digital dashboards for real-time insight
- Setting performance targets and stretch goals
- Avoiding metric gaming and misalignment
- Linking metrics to daily management reviews
- Using data to justify improvement investments
- Reporting progress to executives and boards
- Creating scorecards for departments and teams
- Ensuring data accuracy and consistency
- Using simulation to forecast improvement impact
Module 13: Integrating Lean with Digital Technologies - Understanding Industry 4.0 and its relationship to lean
- Using IoT sensors for real-time monitoring
- Applying lean principles to automation projects
- Ensuring technology supports flow, not complexity
- Using digital twins for process simulation
- Implementing paperless workflows and mobile reporting
- Automating data collection for VSM and OEE
- Integrating lean with MES and SCADA systems
- Using AI for predictive maintenance and anomaly detection
- Reducing digital waste: redundant systems, poor interfaces
- Creating lean UX for operator-facing software
- Training teams on new digital tools without disruption
- Scaling improvement insights across global sites
- Measuring ROI of digital lean initiatives
- Future-proofing your skills in smart manufacturing
Module 14: Personal Lean Leadership Development - Assessing your current lean knowledge and gaps
- Defining your personal improvement mission
- Developing a personal roadmap for mastery
- Building confidence in leading change
- Practising lean communication and active listening
- Giving feedback that drives improvement
- Using coaching questions to unlock team potential
- Managing up: Influencing without authority
- Creating your personal brand as a continuous improver
- Documenting achievements for performance reviews
- Preparing for promotion into operations leadership
- Expanding your network with lean professionals
- Presenting your work to senior executives
- Using storytelling to make data compelling
- Staying current with evolving best practices
Module 15: Real-World Application and Capstone Project - Choosing a high-impact project in your current role
- Defining scope, objectives, and success criteria
- Gaining stakeholder buy-in and alignment
- Conducting a baseline assessment
- Applying lean tools: VSM, 5S, SMED, Kaizen
- Leading a cross-functional team through implementation
- Tracking financial and operational outcomes
- Documenting lessons learned and challenges
- Creating a sustainability plan
- Developing a board-ready presentation
- Measuring ROI and payback period
- Submitting your project for review
- Receiving expert feedback and recommendations
- Revising and finalising your capstone
- Adding your project to your professional portfolio
Module 16: Certification, Career Advancement & Next Steps - Preparing for your Certificate of Completion submission
- Understanding the assessment criteria from The Art of Service
- Formatting your capstone project for professional review
- Submitting your work through the certification portal
- Receiving your verified Certificate of Completion
- Adding the credential to your CV, LinkedIn, and résumé
- Drafting achievement statements for performance reviews
- Breaking into elite operations roles with lean differentiation
- Negotiating salary based on certified expertise
- Applying for roles: Continuous Improvement Manager, Lean Engineer, Operations Director
- Transitioning from technical to strategic leadership
- Accessing alumni resources and job boards
- Joining lean professional networks and associations
- Planning your next learning milestone
- Lifetime access: Updating your skills as lean evolves
- Understanding Sort, Set in Order, Shine, Standardise, Sustain
- Defining red tagging and inventory rationalisation
- Creating visual workplaces with shadow boards and labels
- Designing efficient tool and material locations
- Implementing cleaning as inspection
- Documenting standards with photo-based checklists
- Developing daily, weekly, monthly 5S routines
- Conducting 5S audits and scoring systems
- Engaging teams in ownership and accountability
- Using 5S to reduce search time and errors
- Linking 5S to safety and quality performance
- Scaling 5S across departments and facilities
- Measuring before-and-after results: Floor space, time savings
- Overcoming resistance to workplace changes
- Automating reminders and audit tracking
Module 4: Standardised Work and Visual Management - Defining standardised work as a foundation for improvement
- Creating standard operating procedures with clear visual cues
- Developing work combination charts and sequence sheets
- Using cycle time, takt time, and work-in-progress alignment
- Designing process control boards
- Implementing Andon systems for real-time issue escalation
- Creating performance dashboards with OEE, yield, downtime
- Establishing visual controls for inventory and kanban
- Using colour coding for status, safety, and routing
- Training teams on visual discipline and compliance
- Linking standards to onboarding and cross-training
- Using visual management to reduce supervisor walkarounds
- Ensuring standards evolve with process changes
- Balancing flexibility with consistency
- Measuring adherence and impact on throughput
Module 5: Kaizen and Continuous Improvement - Understanding the philosophy of kaizen vs breakthrough improvement
- Running effective daily kaizen huddles
- Training team members to identify improvement ideas
- Implementing suggestion systems with follow-up discipline
- Conducting rapid improvement events (RIEs)
- Planning a kaizen week: Scope, team, schedule
- Facilitation techniques for cross-functional teams
- Using PDCA cycles within improvement events
- Implementing changes in real time with minimal downtime
- Documenting results and handover to operations
- Tracking kaizen impact on cost, quality, safety
- Recognising and rewarding contributor engagement
- Building a culture where everyone improves everything
- Linking kaizen to performance metrics and goals
- Sustaining momentum beyond the event
Module 6: Just-In-Time (JIT) and Pull Systems - Principles of Just-In-Time production
- Differences between push and pull systems
- Designing kanban systems: Card, bin, electronic
- Calculating kanban quantities and replenishment triggers
- Implementing supermarket pull systems
- Managing mixed-model production with JIT
- Reducing batch sizes and changeover times
- Aligning JIT with supplier delivery schedules
- Handling demand fluctuations in pull systems
- Applying JIT principles beyond manufacturing
- Overcoming inventory dependency culture
- Measuring JIT success: Inventory turns, stockouts, fill rates
- Integrating JIT with ERP and MRP systems
- Using visual signals to manage flow
- Avoiding common JIT implementation pitfalls
Module 7: Total Productive Maintenance (TPM) - Principles of operator-led maintenance
- Defining the 8 pillars of TPM
- Calculating and improving Overall Equipment Effectiveness (OEE)
- Measuring availability, performance, quality losses
- Implementing autonomous maintenance routines
- Developing maintenance standard work
- Conducting root cause analysis on equipment failures
- Reducing unplanned downtime using predictive techniques
- Creating equipment history logs and repair tracking
- Training operators on basic care and inspection
- Establishing cross-functional PM teams
- Using FMEA to anticipate failure modes
- Linking TPM to safety and environmental standards
- Tracking MTBF and MTTR trends
- Reporting TPM progress to leadership
Module 8: SMED – Single-Minute Exchange of Dies - Understanding internal vs external setup activities
- Mapping the current changeover process
- Converting internal steps to external preparation
- Standardising tools and attachments
- Implementing quick-connect utilities (air, power, data)
- Using pre-staged carts and kits
- Training teams on standardised changeover sequences
- Reducing human error with checklist enforcement
- Measuring setup time reduction and capacity gain
- Scaling SMED across similar machines and lines
- Integrating SMED with production scheduling
- Reducing minimum economic batch size
- Creating visual setup guides and instructional aids
- Engaging maintenance and engineering support
- Tracking financial impact: Throughput, inventory, responsiveness
Module 9: Lean Tools for Quality and Problem Solving - Integrating quality into lean systems
- Using Poka-Yoke for mistake-proofing
- Designing fail-safe mechanisms and sensors
- Applying the 5 Whys for root cause discovery
- Constructing fishbone (Ishikawa) diagrams
- Running effective problem-solving workshops
- Implementing A3 thinking for structured reporting
- Using Pareto analysis to prioritise defects
- Mapping defect flow with spaghetti diagrams
- Reducing rework and scrap through process control
- Linking quality metrics to operator incentives
- Creating standard response protocols for non-conformances
- Documenting lessons learned in a knowledge repository
- Using control charts for process stability
- Preventing recurrence through system changes
Module 10: Leading Lean Transformation - Diagnosing organisational readiness for change
- Building a lean vision aligned with business goals
- Creating a multi-year rollout roadmap
- Establishing a Lean Steering Committee
- Defining roles: Lean champions, facilitators, sponsors
- Developing a lean communication strategy
- Running pilot programs to demonstrate quick wins
- Measuring transformation progress with KPIs
- Using balanced scorecards for holistic tracking
- Scaling success from one line to the enterprise
- Managing resistance with empathy and data
- Developing internal coaching capability
- Integrating lean with digital transformation
- Aligning performance management with lean behaviours
- Institutionalising lean through policy and structure
Module 11: Lean in Supply Chain and Logistics - Extending lean principles beyond the factory floor
- Mapping end-to-end supply chain value streams
- Applying JIT to inbound and outbound logistics
- Designing milk-run delivery systems
- Reducing lead time in material handling
- Improving warehouse layout and flow
- Implementing cross-docking and flow-through operations
- Using kanban with suppliers and vendors
- Managing consignment and vendor-managed inventory
- Reducing transit damage and handling waste
- Integrating lean with ERP and WMS platforms
- Collaborating with logistics partners on improvement
- Measuring logistics performance: On-time delivery, fill rate
- Using data to negotiate better contracts
- Creating visibility across the extended enterprise
Module 12: Advanced Lean Analytics and Metrics - Selecting the right metrics for your goals
- Differentiating lagging vs leading indicators
- Calculating OEE, TEEP, and utilisation
- Tracking cycle time, takt time, and throughput
- Measuring first-pass yield and rework rates
- Using downtime codes for root cause analysis
- Building digital dashboards for real-time insight
- Setting performance targets and stretch goals
- Avoiding metric gaming and misalignment
- Linking metrics to daily management reviews
- Using data to justify improvement investments
- Reporting progress to executives and boards
- Creating scorecards for departments and teams
- Ensuring data accuracy and consistency
- Using simulation to forecast improvement impact
Module 13: Integrating Lean with Digital Technologies - Understanding Industry 4.0 and its relationship to lean
- Using IoT sensors for real-time monitoring
- Applying lean principles to automation projects
- Ensuring technology supports flow, not complexity
- Using digital twins for process simulation
- Implementing paperless workflows and mobile reporting
- Automating data collection for VSM and OEE
- Integrating lean with MES and SCADA systems
- Using AI for predictive maintenance and anomaly detection
- Reducing digital waste: redundant systems, poor interfaces
- Creating lean UX for operator-facing software
- Training teams on new digital tools without disruption
- Scaling improvement insights across global sites
- Measuring ROI of digital lean initiatives
- Future-proofing your skills in smart manufacturing
Module 14: Personal Lean Leadership Development - Assessing your current lean knowledge and gaps
- Defining your personal improvement mission
- Developing a personal roadmap for mastery
- Building confidence in leading change
- Practising lean communication and active listening
- Giving feedback that drives improvement
- Using coaching questions to unlock team potential
- Managing up: Influencing without authority
- Creating your personal brand as a continuous improver
- Documenting achievements for performance reviews
- Preparing for promotion into operations leadership
- Expanding your network with lean professionals
- Presenting your work to senior executives
- Using storytelling to make data compelling
- Staying current with evolving best practices
Module 15: Real-World Application and Capstone Project - Choosing a high-impact project in your current role
- Defining scope, objectives, and success criteria
- Gaining stakeholder buy-in and alignment
- Conducting a baseline assessment
- Applying lean tools: VSM, 5S, SMED, Kaizen
- Leading a cross-functional team through implementation
- Tracking financial and operational outcomes
- Documenting lessons learned and challenges
- Creating a sustainability plan
- Developing a board-ready presentation
- Measuring ROI and payback period
- Submitting your project for review
- Receiving expert feedback and recommendations
- Revising and finalising your capstone
- Adding your project to your professional portfolio
Module 16: Certification, Career Advancement & Next Steps - Preparing for your Certificate of Completion submission
- Understanding the assessment criteria from The Art of Service
- Formatting your capstone project for professional review
- Submitting your work through the certification portal
- Receiving your verified Certificate of Completion
- Adding the credential to your CV, LinkedIn, and résumé
- Drafting achievement statements for performance reviews
- Breaking into elite operations roles with lean differentiation
- Negotiating salary based on certified expertise
- Applying for roles: Continuous Improvement Manager, Lean Engineer, Operations Director
- Transitioning from technical to strategic leadership
- Accessing alumni resources and job boards
- Joining lean professional networks and associations
- Planning your next learning milestone
- Lifetime access: Updating your skills as lean evolves
- Understanding the philosophy of kaizen vs breakthrough improvement
- Running effective daily kaizen huddles
- Training team members to identify improvement ideas
- Implementing suggestion systems with follow-up discipline
- Conducting rapid improvement events (RIEs)
- Planning a kaizen week: Scope, team, schedule
- Facilitation techniques for cross-functional teams
- Using PDCA cycles within improvement events
- Implementing changes in real time with minimal downtime
- Documenting results and handover to operations
- Tracking kaizen impact on cost, quality, safety
- Recognising and rewarding contributor engagement
- Building a culture where everyone improves everything
- Linking kaizen to performance metrics and goals
- Sustaining momentum beyond the event
Module 6: Just-In-Time (JIT) and Pull Systems - Principles of Just-In-Time production
- Differences between push and pull systems
- Designing kanban systems: Card, bin, electronic
- Calculating kanban quantities and replenishment triggers
- Implementing supermarket pull systems
- Managing mixed-model production with JIT
- Reducing batch sizes and changeover times
- Aligning JIT with supplier delivery schedules
- Handling demand fluctuations in pull systems
- Applying JIT principles beyond manufacturing
- Overcoming inventory dependency culture
- Measuring JIT success: Inventory turns, stockouts, fill rates
- Integrating JIT with ERP and MRP systems
- Using visual signals to manage flow
- Avoiding common JIT implementation pitfalls
Module 7: Total Productive Maintenance (TPM) - Principles of operator-led maintenance
- Defining the 8 pillars of TPM
- Calculating and improving Overall Equipment Effectiveness (OEE)
- Measuring availability, performance, quality losses
- Implementing autonomous maintenance routines
- Developing maintenance standard work
- Conducting root cause analysis on equipment failures
- Reducing unplanned downtime using predictive techniques
- Creating equipment history logs and repair tracking
- Training operators on basic care and inspection
- Establishing cross-functional PM teams
- Using FMEA to anticipate failure modes
- Linking TPM to safety and environmental standards
- Tracking MTBF and MTTR trends
- Reporting TPM progress to leadership
Module 8: SMED – Single-Minute Exchange of Dies - Understanding internal vs external setup activities
- Mapping the current changeover process
- Converting internal steps to external preparation
- Standardising tools and attachments
- Implementing quick-connect utilities (air, power, data)
- Using pre-staged carts and kits
- Training teams on standardised changeover sequences
- Reducing human error with checklist enforcement
- Measuring setup time reduction and capacity gain
- Scaling SMED across similar machines and lines
- Integrating SMED with production scheduling
- Reducing minimum economic batch size
- Creating visual setup guides and instructional aids
- Engaging maintenance and engineering support
- Tracking financial impact: Throughput, inventory, responsiveness
Module 9: Lean Tools for Quality and Problem Solving - Integrating quality into lean systems
- Using Poka-Yoke for mistake-proofing
- Designing fail-safe mechanisms and sensors
- Applying the 5 Whys for root cause discovery
- Constructing fishbone (Ishikawa) diagrams
- Running effective problem-solving workshops
- Implementing A3 thinking for structured reporting
- Using Pareto analysis to prioritise defects
- Mapping defect flow with spaghetti diagrams
- Reducing rework and scrap through process control
- Linking quality metrics to operator incentives
- Creating standard response protocols for non-conformances
- Documenting lessons learned in a knowledge repository
- Using control charts for process stability
- Preventing recurrence through system changes
Module 10: Leading Lean Transformation - Diagnosing organisational readiness for change
- Building a lean vision aligned with business goals
- Creating a multi-year rollout roadmap
- Establishing a Lean Steering Committee
- Defining roles: Lean champions, facilitators, sponsors
- Developing a lean communication strategy
- Running pilot programs to demonstrate quick wins
- Measuring transformation progress with KPIs
- Using balanced scorecards for holistic tracking
- Scaling success from one line to the enterprise
- Managing resistance with empathy and data
- Developing internal coaching capability
- Integrating lean with digital transformation
- Aligning performance management with lean behaviours
- Institutionalising lean through policy and structure
Module 11: Lean in Supply Chain and Logistics - Extending lean principles beyond the factory floor
- Mapping end-to-end supply chain value streams
- Applying JIT to inbound and outbound logistics
- Designing milk-run delivery systems
- Reducing lead time in material handling
- Improving warehouse layout and flow
- Implementing cross-docking and flow-through operations
- Using kanban with suppliers and vendors
- Managing consignment and vendor-managed inventory
- Reducing transit damage and handling waste
- Integrating lean with ERP and WMS platforms
- Collaborating with logistics partners on improvement
- Measuring logistics performance: On-time delivery, fill rate
- Using data to negotiate better contracts
- Creating visibility across the extended enterprise
Module 12: Advanced Lean Analytics and Metrics - Selecting the right metrics for your goals
- Differentiating lagging vs leading indicators
- Calculating OEE, TEEP, and utilisation
- Tracking cycle time, takt time, and throughput
- Measuring first-pass yield and rework rates
- Using downtime codes for root cause analysis
- Building digital dashboards for real-time insight
- Setting performance targets and stretch goals
- Avoiding metric gaming and misalignment
- Linking metrics to daily management reviews
- Using data to justify improvement investments
- Reporting progress to executives and boards
- Creating scorecards for departments and teams
- Ensuring data accuracy and consistency
- Using simulation to forecast improvement impact
Module 13: Integrating Lean with Digital Technologies - Understanding Industry 4.0 and its relationship to lean
- Using IoT sensors for real-time monitoring
- Applying lean principles to automation projects
- Ensuring technology supports flow, not complexity
- Using digital twins for process simulation
- Implementing paperless workflows and mobile reporting
- Automating data collection for VSM and OEE
- Integrating lean with MES and SCADA systems
- Using AI for predictive maintenance and anomaly detection
- Reducing digital waste: redundant systems, poor interfaces
- Creating lean UX for operator-facing software
- Training teams on new digital tools without disruption
- Scaling improvement insights across global sites
- Measuring ROI of digital lean initiatives
- Future-proofing your skills in smart manufacturing
Module 14: Personal Lean Leadership Development - Assessing your current lean knowledge and gaps
- Defining your personal improvement mission
- Developing a personal roadmap for mastery
- Building confidence in leading change
- Practising lean communication and active listening
- Giving feedback that drives improvement
- Using coaching questions to unlock team potential
- Managing up: Influencing without authority
- Creating your personal brand as a continuous improver
- Documenting achievements for performance reviews
- Preparing for promotion into operations leadership
- Expanding your network with lean professionals
- Presenting your work to senior executives
- Using storytelling to make data compelling
- Staying current with evolving best practices
Module 15: Real-World Application and Capstone Project - Choosing a high-impact project in your current role
- Defining scope, objectives, and success criteria
- Gaining stakeholder buy-in and alignment
- Conducting a baseline assessment
- Applying lean tools: VSM, 5S, SMED, Kaizen
- Leading a cross-functional team through implementation
- Tracking financial and operational outcomes
- Documenting lessons learned and challenges
- Creating a sustainability plan
- Developing a board-ready presentation
- Measuring ROI and payback period
- Submitting your project for review
- Receiving expert feedback and recommendations
- Revising and finalising your capstone
- Adding your project to your professional portfolio
Module 16: Certification, Career Advancement & Next Steps - Preparing for your Certificate of Completion submission
- Understanding the assessment criteria from The Art of Service
- Formatting your capstone project for professional review
- Submitting your work through the certification portal
- Receiving your verified Certificate of Completion
- Adding the credential to your CV, LinkedIn, and résumé
- Drafting achievement statements for performance reviews
- Breaking into elite operations roles with lean differentiation
- Negotiating salary based on certified expertise
- Applying for roles: Continuous Improvement Manager, Lean Engineer, Operations Director
- Transitioning from technical to strategic leadership
- Accessing alumni resources and job boards
- Joining lean professional networks and associations
- Planning your next learning milestone
- Lifetime access: Updating your skills as lean evolves
- Principles of operator-led maintenance
- Defining the 8 pillars of TPM
- Calculating and improving Overall Equipment Effectiveness (OEE)
- Measuring availability, performance, quality losses
- Implementing autonomous maintenance routines
- Developing maintenance standard work
- Conducting root cause analysis on equipment failures
- Reducing unplanned downtime using predictive techniques
- Creating equipment history logs and repair tracking
- Training operators on basic care and inspection
- Establishing cross-functional PM teams
- Using FMEA to anticipate failure modes
- Linking TPM to safety and environmental standards
- Tracking MTBF and MTTR trends
- Reporting TPM progress to leadership
Module 8: SMED – Single-Minute Exchange of Dies - Understanding internal vs external setup activities
- Mapping the current changeover process
- Converting internal steps to external preparation
- Standardising tools and attachments
- Implementing quick-connect utilities (air, power, data)
- Using pre-staged carts and kits
- Training teams on standardised changeover sequences
- Reducing human error with checklist enforcement
- Measuring setup time reduction and capacity gain
- Scaling SMED across similar machines and lines
- Integrating SMED with production scheduling
- Reducing minimum economic batch size
- Creating visual setup guides and instructional aids
- Engaging maintenance and engineering support
- Tracking financial impact: Throughput, inventory, responsiveness
Module 9: Lean Tools for Quality and Problem Solving - Integrating quality into lean systems
- Using Poka-Yoke for mistake-proofing
- Designing fail-safe mechanisms and sensors
- Applying the 5 Whys for root cause discovery
- Constructing fishbone (Ishikawa) diagrams
- Running effective problem-solving workshops
- Implementing A3 thinking for structured reporting
- Using Pareto analysis to prioritise defects
- Mapping defect flow with spaghetti diagrams
- Reducing rework and scrap through process control
- Linking quality metrics to operator incentives
- Creating standard response protocols for non-conformances
- Documenting lessons learned in a knowledge repository
- Using control charts for process stability
- Preventing recurrence through system changes
Module 10: Leading Lean Transformation - Diagnosing organisational readiness for change
- Building a lean vision aligned with business goals
- Creating a multi-year rollout roadmap
- Establishing a Lean Steering Committee
- Defining roles: Lean champions, facilitators, sponsors
- Developing a lean communication strategy
- Running pilot programs to demonstrate quick wins
- Measuring transformation progress with KPIs
- Using balanced scorecards for holistic tracking
- Scaling success from one line to the enterprise
- Managing resistance with empathy and data
- Developing internal coaching capability
- Integrating lean with digital transformation
- Aligning performance management with lean behaviours
- Institutionalising lean through policy and structure
Module 11: Lean in Supply Chain and Logistics - Extending lean principles beyond the factory floor
- Mapping end-to-end supply chain value streams
- Applying JIT to inbound and outbound logistics
- Designing milk-run delivery systems
- Reducing lead time in material handling
- Improving warehouse layout and flow
- Implementing cross-docking and flow-through operations
- Using kanban with suppliers and vendors
- Managing consignment and vendor-managed inventory
- Reducing transit damage and handling waste
- Integrating lean with ERP and WMS platforms
- Collaborating with logistics partners on improvement
- Measuring logistics performance: On-time delivery, fill rate
- Using data to negotiate better contracts
- Creating visibility across the extended enterprise
Module 12: Advanced Lean Analytics and Metrics - Selecting the right metrics for your goals
- Differentiating lagging vs leading indicators
- Calculating OEE, TEEP, and utilisation
- Tracking cycle time, takt time, and throughput
- Measuring first-pass yield and rework rates
- Using downtime codes for root cause analysis
- Building digital dashboards for real-time insight
- Setting performance targets and stretch goals
- Avoiding metric gaming and misalignment
- Linking metrics to daily management reviews
- Using data to justify improvement investments
- Reporting progress to executives and boards
- Creating scorecards for departments and teams
- Ensuring data accuracy and consistency
- Using simulation to forecast improvement impact
Module 13: Integrating Lean with Digital Technologies - Understanding Industry 4.0 and its relationship to lean
- Using IoT sensors for real-time monitoring
- Applying lean principles to automation projects
- Ensuring technology supports flow, not complexity
- Using digital twins for process simulation
- Implementing paperless workflows and mobile reporting
- Automating data collection for VSM and OEE
- Integrating lean with MES and SCADA systems
- Using AI for predictive maintenance and anomaly detection
- Reducing digital waste: redundant systems, poor interfaces
- Creating lean UX for operator-facing software
- Training teams on new digital tools without disruption
- Scaling improvement insights across global sites
- Measuring ROI of digital lean initiatives
- Future-proofing your skills in smart manufacturing
Module 14: Personal Lean Leadership Development - Assessing your current lean knowledge and gaps
- Defining your personal improvement mission
- Developing a personal roadmap for mastery
- Building confidence in leading change
- Practising lean communication and active listening
- Giving feedback that drives improvement
- Using coaching questions to unlock team potential
- Managing up: Influencing without authority
- Creating your personal brand as a continuous improver
- Documenting achievements for performance reviews
- Preparing for promotion into operations leadership
- Expanding your network with lean professionals
- Presenting your work to senior executives
- Using storytelling to make data compelling
- Staying current with evolving best practices
Module 15: Real-World Application and Capstone Project - Choosing a high-impact project in your current role
- Defining scope, objectives, and success criteria
- Gaining stakeholder buy-in and alignment
- Conducting a baseline assessment
- Applying lean tools: VSM, 5S, SMED, Kaizen
- Leading a cross-functional team through implementation
- Tracking financial and operational outcomes
- Documenting lessons learned and challenges
- Creating a sustainability plan
- Developing a board-ready presentation
- Measuring ROI and payback period
- Submitting your project for review
- Receiving expert feedback and recommendations
- Revising and finalising your capstone
- Adding your project to your professional portfolio
Module 16: Certification, Career Advancement & Next Steps - Preparing for your Certificate of Completion submission
- Understanding the assessment criteria from The Art of Service
- Formatting your capstone project for professional review
- Submitting your work through the certification portal
- Receiving your verified Certificate of Completion
- Adding the credential to your CV, LinkedIn, and résumé
- Drafting achievement statements for performance reviews
- Breaking into elite operations roles with lean differentiation
- Negotiating salary based on certified expertise
- Applying for roles: Continuous Improvement Manager, Lean Engineer, Operations Director
- Transitioning from technical to strategic leadership
- Accessing alumni resources and job boards
- Joining lean professional networks and associations
- Planning your next learning milestone
- Lifetime access: Updating your skills as lean evolves
- Integrating quality into lean systems
- Using Poka-Yoke for mistake-proofing
- Designing fail-safe mechanisms and sensors
- Applying the 5 Whys for root cause discovery
- Constructing fishbone (Ishikawa) diagrams
- Running effective problem-solving workshops
- Implementing A3 thinking for structured reporting
- Using Pareto analysis to prioritise defects
- Mapping defect flow with spaghetti diagrams
- Reducing rework and scrap through process control
- Linking quality metrics to operator incentives
- Creating standard response protocols for non-conformances
- Documenting lessons learned in a knowledge repository
- Using control charts for process stability
- Preventing recurrence through system changes
Module 10: Leading Lean Transformation - Diagnosing organisational readiness for change
- Building a lean vision aligned with business goals
- Creating a multi-year rollout roadmap
- Establishing a Lean Steering Committee
- Defining roles: Lean champions, facilitators, sponsors
- Developing a lean communication strategy
- Running pilot programs to demonstrate quick wins
- Measuring transformation progress with KPIs
- Using balanced scorecards for holistic tracking
- Scaling success from one line to the enterprise
- Managing resistance with empathy and data
- Developing internal coaching capability
- Integrating lean with digital transformation
- Aligning performance management with lean behaviours
- Institutionalising lean through policy and structure
Module 11: Lean in Supply Chain and Logistics - Extending lean principles beyond the factory floor
- Mapping end-to-end supply chain value streams
- Applying JIT to inbound and outbound logistics
- Designing milk-run delivery systems
- Reducing lead time in material handling
- Improving warehouse layout and flow
- Implementing cross-docking and flow-through operations
- Using kanban with suppliers and vendors
- Managing consignment and vendor-managed inventory
- Reducing transit damage and handling waste
- Integrating lean with ERP and WMS platforms
- Collaborating with logistics partners on improvement
- Measuring logistics performance: On-time delivery, fill rate
- Using data to negotiate better contracts
- Creating visibility across the extended enterprise
Module 12: Advanced Lean Analytics and Metrics - Selecting the right metrics for your goals
- Differentiating lagging vs leading indicators
- Calculating OEE, TEEP, and utilisation
- Tracking cycle time, takt time, and throughput
- Measuring first-pass yield and rework rates
- Using downtime codes for root cause analysis
- Building digital dashboards for real-time insight
- Setting performance targets and stretch goals
- Avoiding metric gaming and misalignment
- Linking metrics to daily management reviews
- Using data to justify improvement investments
- Reporting progress to executives and boards
- Creating scorecards for departments and teams
- Ensuring data accuracy and consistency
- Using simulation to forecast improvement impact
Module 13: Integrating Lean with Digital Technologies - Understanding Industry 4.0 and its relationship to lean
- Using IoT sensors for real-time monitoring
- Applying lean principles to automation projects
- Ensuring technology supports flow, not complexity
- Using digital twins for process simulation
- Implementing paperless workflows and mobile reporting
- Automating data collection for VSM and OEE
- Integrating lean with MES and SCADA systems
- Using AI for predictive maintenance and anomaly detection
- Reducing digital waste: redundant systems, poor interfaces
- Creating lean UX for operator-facing software
- Training teams on new digital tools without disruption
- Scaling improvement insights across global sites
- Measuring ROI of digital lean initiatives
- Future-proofing your skills in smart manufacturing
Module 14: Personal Lean Leadership Development - Assessing your current lean knowledge and gaps
- Defining your personal improvement mission
- Developing a personal roadmap for mastery
- Building confidence in leading change
- Practising lean communication and active listening
- Giving feedback that drives improvement
- Using coaching questions to unlock team potential
- Managing up: Influencing without authority
- Creating your personal brand as a continuous improver
- Documenting achievements for performance reviews
- Preparing for promotion into operations leadership
- Expanding your network with lean professionals
- Presenting your work to senior executives
- Using storytelling to make data compelling
- Staying current with evolving best practices
Module 15: Real-World Application and Capstone Project - Choosing a high-impact project in your current role
- Defining scope, objectives, and success criteria
- Gaining stakeholder buy-in and alignment
- Conducting a baseline assessment
- Applying lean tools: VSM, 5S, SMED, Kaizen
- Leading a cross-functional team through implementation
- Tracking financial and operational outcomes
- Documenting lessons learned and challenges
- Creating a sustainability plan
- Developing a board-ready presentation
- Measuring ROI and payback period
- Submitting your project for review
- Receiving expert feedback and recommendations
- Revising and finalising your capstone
- Adding your project to your professional portfolio
Module 16: Certification, Career Advancement & Next Steps - Preparing for your Certificate of Completion submission
- Understanding the assessment criteria from The Art of Service
- Formatting your capstone project for professional review
- Submitting your work through the certification portal
- Receiving your verified Certificate of Completion
- Adding the credential to your CV, LinkedIn, and résumé
- Drafting achievement statements for performance reviews
- Breaking into elite operations roles with lean differentiation
- Negotiating salary based on certified expertise
- Applying for roles: Continuous Improvement Manager, Lean Engineer, Operations Director
- Transitioning from technical to strategic leadership
- Accessing alumni resources and job boards
- Joining lean professional networks and associations
- Planning your next learning milestone
- Lifetime access: Updating your skills as lean evolves
- Extending lean principles beyond the factory floor
- Mapping end-to-end supply chain value streams
- Applying JIT to inbound and outbound logistics
- Designing milk-run delivery systems
- Reducing lead time in material handling
- Improving warehouse layout and flow
- Implementing cross-docking and flow-through operations
- Using kanban with suppliers and vendors
- Managing consignment and vendor-managed inventory
- Reducing transit damage and handling waste
- Integrating lean with ERP and WMS platforms
- Collaborating with logistics partners on improvement
- Measuring logistics performance: On-time delivery, fill rate
- Using data to negotiate better contracts
- Creating visibility across the extended enterprise
Module 12: Advanced Lean Analytics and Metrics - Selecting the right metrics for your goals
- Differentiating lagging vs leading indicators
- Calculating OEE, TEEP, and utilisation
- Tracking cycle time, takt time, and throughput
- Measuring first-pass yield and rework rates
- Using downtime codes for root cause analysis
- Building digital dashboards for real-time insight
- Setting performance targets and stretch goals
- Avoiding metric gaming and misalignment
- Linking metrics to daily management reviews
- Using data to justify improvement investments
- Reporting progress to executives and boards
- Creating scorecards for departments and teams
- Ensuring data accuracy and consistency
- Using simulation to forecast improvement impact
Module 13: Integrating Lean with Digital Technologies - Understanding Industry 4.0 and its relationship to lean
- Using IoT sensors for real-time monitoring
- Applying lean principles to automation projects
- Ensuring technology supports flow, not complexity
- Using digital twins for process simulation
- Implementing paperless workflows and mobile reporting
- Automating data collection for VSM and OEE
- Integrating lean with MES and SCADA systems
- Using AI for predictive maintenance and anomaly detection
- Reducing digital waste: redundant systems, poor interfaces
- Creating lean UX for operator-facing software
- Training teams on new digital tools without disruption
- Scaling improvement insights across global sites
- Measuring ROI of digital lean initiatives
- Future-proofing your skills in smart manufacturing
Module 14: Personal Lean Leadership Development - Assessing your current lean knowledge and gaps
- Defining your personal improvement mission
- Developing a personal roadmap for mastery
- Building confidence in leading change
- Practising lean communication and active listening
- Giving feedback that drives improvement
- Using coaching questions to unlock team potential
- Managing up: Influencing without authority
- Creating your personal brand as a continuous improver
- Documenting achievements for performance reviews
- Preparing for promotion into operations leadership
- Expanding your network with lean professionals
- Presenting your work to senior executives
- Using storytelling to make data compelling
- Staying current with evolving best practices
Module 15: Real-World Application and Capstone Project - Choosing a high-impact project in your current role
- Defining scope, objectives, and success criteria
- Gaining stakeholder buy-in and alignment
- Conducting a baseline assessment
- Applying lean tools: VSM, 5S, SMED, Kaizen
- Leading a cross-functional team through implementation
- Tracking financial and operational outcomes
- Documenting lessons learned and challenges
- Creating a sustainability plan
- Developing a board-ready presentation
- Measuring ROI and payback period
- Submitting your project for review
- Receiving expert feedback and recommendations
- Revising and finalising your capstone
- Adding your project to your professional portfolio
Module 16: Certification, Career Advancement & Next Steps - Preparing for your Certificate of Completion submission
- Understanding the assessment criteria from The Art of Service
- Formatting your capstone project for professional review
- Submitting your work through the certification portal
- Receiving your verified Certificate of Completion
- Adding the credential to your CV, LinkedIn, and résumé
- Drafting achievement statements for performance reviews
- Breaking into elite operations roles with lean differentiation
- Negotiating salary based on certified expertise
- Applying for roles: Continuous Improvement Manager, Lean Engineer, Operations Director
- Transitioning from technical to strategic leadership
- Accessing alumni resources and job boards
- Joining lean professional networks and associations
- Planning your next learning milestone
- Lifetime access: Updating your skills as lean evolves
- Understanding Industry 4.0 and its relationship to lean
- Using IoT sensors for real-time monitoring
- Applying lean principles to automation projects
- Ensuring technology supports flow, not complexity
- Using digital twins for process simulation
- Implementing paperless workflows and mobile reporting
- Automating data collection for VSM and OEE
- Integrating lean with MES and SCADA systems
- Using AI for predictive maintenance and anomaly detection
- Reducing digital waste: redundant systems, poor interfaces
- Creating lean UX for operator-facing software
- Training teams on new digital tools without disruption
- Scaling improvement insights across global sites
- Measuring ROI of digital lean initiatives
- Future-proofing your skills in smart manufacturing
Module 14: Personal Lean Leadership Development - Assessing your current lean knowledge and gaps
- Defining your personal improvement mission
- Developing a personal roadmap for mastery
- Building confidence in leading change
- Practising lean communication and active listening
- Giving feedback that drives improvement
- Using coaching questions to unlock team potential
- Managing up: Influencing without authority
- Creating your personal brand as a continuous improver
- Documenting achievements for performance reviews
- Preparing for promotion into operations leadership
- Expanding your network with lean professionals
- Presenting your work to senior executives
- Using storytelling to make data compelling
- Staying current with evolving best practices
Module 15: Real-World Application and Capstone Project - Choosing a high-impact project in your current role
- Defining scope, objectives, and success criteria
- Gaining stakeholder buy-in and alignment
- Conducting a baseline assessment
- Applying lean tools: VSM, 5S, SMED, Kaizen
- Leading a cross-functional team through implementation
- Tracking financial and operational outcomes
- Documenting lessons learned and challenges
- Creating a sustainability plan
- Developing a board-ready presentation
- Measuring ROI and payback period
- Submitting your project for review
- Receiving expert feedback and recommendations
- Revising and finalising your capstone
- Adding your project to your professional portfolio
Module 16: Certification, Career Advancement & Next Steps - Preparing for your Certificate of Completion submission
- Understanding the assessment criteria from The Art of Service
- Formatting your capstone project for professional review
- Submitting your work through the certification portal
- Receiving your verified Certificate of Completion
- Adding the credential to your CV, LinkedIn, and résumé
- Drafting achievement statements for performance reviews
- Breaking into elite operations roles with lean differentiation
- Negotiating salary based on certified expertise
- Applying for roles: Continuous Improvement Manager, Lean Engineer, Operations Director
- Transitioning from technical to strategic leadership
- Accessing alumni resources and job boards
- Joining lean professional networks and associations
- Planning your next learning milestone
- Lifetime access: Updating your skills as lean evolves
- Choosing a high-impact project in your current role
- Defining scope, objectives, and success criteria
- Gaining stakeholder buy-in and alignment
- Conducting a baseline assessment
- Applying lean tools: VSM, 5S, SMED, Kaizen
- Leading a cross-functional team through implementation
- Tracking financial and operational outcomes
- Documenting lessons learned and challenges
- Creating a sustainability plan
- Developing a board-ready presentation
- Measuring ROI and payback period
- Submitting your project for review
- Receiving expert feedback and recommendations
- Revising and finalising your capstone
- Adding your project to your professional portfolio