How to implement Lean Manufacturing

A three day training course which identifies how to implement lean.  Suitable for senior executives/managers which focusses on the key implementation and people skills.

Why introduce Lean Manufacturing?

  • Increased Customer Satisfaction –more repeat business
  • Reduced Waste –shorter lead times, lower costs
  • Improved Profitability
  • Improved Process Control –more right first time
  • Company Wide Team Work – breaking down functional barriers to success

What you will learn

At the conclusion of the how to implement lean manufacturing training course each delegate should be able to:-

  • Recognise ‘waste’ and non-value added activities throughout their operation
  • Implement and maintain a departmental wide visual 5S programme
  • Introduce a basic pull scheduling system e.g. Kanban
  • Design and set up a lean manufacturing cell
  • Identify how mistake proofing could be used in a zero quality control system
  • Follow a standard process to significantly reduce machine change-over times
  • Identify a programme to maintain production equipment
  • Generate value stream maps of their own manufacturing processes to highlight waste and suggest improvements

Course Content

Introduction – Setting the Scene

  • Introduction to Lean – What is it all about?
  • Definitions – Jargon Busting
  • What benefits can we realistically expect from a company wide lean programme?

Lean Tools – An Overview

A practical session where interactive business ‘games’ are used to demonstrate lean tools in action including:

  • 7 Wastes
  • 5S and Visual Factory
  • Kanban
  • Cellular Manufacturing
  • Zero Quality Control
  • Single Minute Exchange of Dies (SMED)
  • Total Productive Maintenance (TPM)
  • Value Stream Mapping

The Implementation Plan

  • How to generate a lean implementation plan
  • Selection & introduction of appropriate Key Performance Indicators (KPIs)
  • How to sustain lean – to ensure its not perceived as just another fad
  • Phased Introduction supported by pilots and reviews
  • Regular, objective review of progress, inhibitors and milestones

People – “Winning the Hearts and Minds”

What is expected of a manager in a lean manufacturing environment?

  • Roles
  • Ownership, Responsibility & Accountability
  • How to bring about a lean environment by effective communication
  • How to create a lean culture with self-managing, empowered teams
  • Initiating Kaizen activities- making it work for your business
  • Breaking down cross functional barriers
  • Dealing with objections from other parties
  • Getting the ‘cynics’ on board the programme
  • Knowing where to start


Workplace Overview –In House Course Only

This session involves spending time as a group ‘walking the job’. It’s about ‘learning to see’ the waste in your business. We accomplish this by spending time in each of your delegates’ departments, teaching them to ‘see’ the areas of waste and discuss improvements which could be made by implementing a lean philosophy.

Following this activity we carry out a group ‘brainstorming’ session to identify possible pilot projects, areas of concern and to generate a lean implementation plan by work area.

This training course is limited to a maximum of twelve delegates. Course costs cover the three training sessions, a comprehensive set of course notes, lunch, refreshments and an attendance certificate.

Our Reviews

Really useful

Review by Charith Jayathilake, CI Engineer, Amsafe

"Really useful because we want to implement lean."

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Customer Reviews

Items 1 to 10 of 10 total

Really useful

Review by Charith Jayathilake, CI Engineer, Amsafe

"Really useful because we want to implement lean."

Engaging Presentation Style

Review by Kevin May, Logistics Manager, Amsafe

"Great, engaging presentation style."

Very Versatile

Review by Pedro Martins, OPEX Team, Amsafe

"Very versatile covering all the aspects/topics that really left us with doubts beforehand. Huge reinforcement of our future perspectives."

Tailor Made

Review by Joolz Brown, Production Engineer, Amsafe

"The course was tailor made for Amsafe."

Tailored to our Requirements

Review by Wendy Rosamund, Opex Team, Amsafe

"I liked the fact the course was tailor made for our small group and that Paul was able to change the lean training to fit our needs."

Thank you Paul

Review by Ojo Adesima, Manufacturing Improvement Technician

"I really enjoyed the course and would like to thank Paul for passing on his experience to me."

Great Trainer

Review by A. Trigg, Production Manager, Johnsons ApparelMaster

"Great trainer, Good Venue, plenty of opportunity to be involved."


Review by Aud Prior, Dept Manager, Siga Electronics

"Paul has much passion on lean - his enthusiasm is infectious,"

Not a dull moment

Review by Fudgie Maynard, Director of Process Improvement, ASG Worldwide

"Very informative and engaging presentation - not a dull moment!"

Excellent Course

Review by Brain Blackburn, Operations Director, TSI Instruments

"Excellent well thought out course, interactive with good examples to back up content."