The Ultimate Lean Training

COURSE MODULES 13 MODULES      (29 Hours)

The purpose of the ALARDI Africa lean training is to equip individuals and organizations with skills to eliminate waste, optimize processes, and maximize customer value, fostering a culture of continuous improvement for better efficiency, lower costs, higher quality, and increased competitiveness. It teaches practical methods to identify non-value-added activities (like defects, waiting, overproduction) and implement standardized, streamlined workflows to achieve operational excellence.

Objectives

The Course will help participants and their organizations address:

• Waste Reduction: Identify and remove the “eight wastes” (defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, extra processing).
• Process Optimization: Streamline workflows to reduce delays, improve throughput, and increase productivity.
• Value Maximization: Focus efforts on activities that customers value and are willing to pay for.
• Continuous Improvement (Kaizen): Develop a mindset where employees constantly seek small, impactful improvements.
• Empowerment: Enable employees to take ownership and solve problems within their own processes.
• Cost Reduction: Lower operational expenses by minimizing resources used for non-value-added tasks.

 

Who Should Attend:

The specific individuals and roles that should attend include:

• Executive and Senior Leadership: CEOs, founders, owners, and C-suite leaders responsible for setting organizational direction and strategy execution.
• Operational and Departmental Managers: VPs, directors, department heads, and managers who oversee daily operations and performance, and are tasked with eliminating waste and improving process flow.
• Process Improvement Specialists: Professionals and teams leading Lean, Agile, Operational Excellence, or Continuous Improvement (CI) efforts, such as Lean Practitioners, Lean Coaches, and Quality Assurance Analysts.
• Project and Team Leaders: Individuals managing cross-functional initiatives and responsible for developing people and fostering team engagement.
• Supervisors and Frontline Staff: Employees at all levels who are involved in critical processes and daily activities and are interested in learning Lean fundamentals to contribute to improvement initiatives.

 

Relevant Industries

Lean principles apply to any organization with repetitive processes, making the course valuable across diverse sectors:

• Manufacturing and Production
• Healthcare and Life Sciences
• IT and Software Development
• Finance and Banking
• Supply Chain and Logistics
• Public Sector and NGOs

 

Organization Benefits

The Organization will gain by:

• Driving a sustainable Lean implementation and embedding a culture of continuous improvement.
• Eliminating wasteful practices, streamlining work, and increasing customer value.
• Translating vision into daily action using systems like visual management and leader standard work.
• Coaching and empowering teams to solve problems independently and align their behaviors with strategic goals.

 

Ultimately, this course helps leaders transition from “firefighting” daily problems to building resilient systems that sustain results. There are typically no formal prerequisites, making it accessible to professionals at various career stages.

 

Personal Benefits

Participants will be able to:

• Understand streamlined workflows for enhanced productivity
• Gain problem-solving skills through Lean methodologies
• Acquire knowledge in waste reduction and resource optimisation
• Implement Lean principles for improved business performance
• Enhance operational efficiency with Lean Training insights
• Develop a Lean mindset for continuous improvement in processes

 

Training Methodology

This course applies a range of proven adult learning techniques to promote deep understanding, engagement, and practical skill development. These include:

• Instructor-led presentations introducing key concepts and models
• Hands-on delegate exercises for real-world application
• Structured group discussions to encourage knowledge sharing
• Scenario-based activities and simulations for decision-making practice

 

Course Outline

Module 1: About Lean

• Path to Value
• Key Lean Terms and Concepts
• Gemba Walk

 

Module 2: Five Steps of Lean Thinking

• Process Stapling
• Lean Temple

 

Module 3: Customers, Processes, and Waste

• What are Customers?
• What is a Process?
• Tension Between VOB and VOC
• What Do We Mean by Value?
• Path to Value
• Dealing with Values
• Eight Wastes of Lean

 

Module 4: Key Lean Metrics

• Introduction to Key Lean Metrics
• Tools and Techniques
• Spaghetti (Movement/Transportation) Diagrams
• Measles Charts
• Lean Triad
• 5S
• What is of 5S
• Steps of 5S
• What is Poka Yoke
• Two Main Types of Poka Yoke
• What is SMED?
• Employing SMED Will Enable You to…
• How SMED Looks Like?
• Voice of Customer (VOC)
• Customer Segmentation
• Four Steps of VOC Methodology and Tools
  • Identify Customers
  • Gather Customer Information
  • Analyse Customer Information
  • Determine Customer Needs
• Customer Segmentation
• SIPOC
• CSandF Web Fulfilment SIPOC
• VOC Step Two: Gather Customer Information
• VOC Step Three: Analyse Customer Information
• Affinity Diagrams
• Overview of the Kano Model
• Kano Model
• Kano Analysis: Budget TV 2012
• VOC Step Four: Determine Customer Needs
• Identifying the Requirements
• What is a Critical to Quality (CTQ)?
• Common Terminology
• Identifying the Root Cause
• Five Whys
• Root Cause Analysis (Fishbone)
• Reverse Fishbone
• Control Frameworks
• Three C’s
• Eight Ds
• Plan Do Check Act
• Introduction to Kaizen
• Kaizen
• Kaizen Philosophy
• Kaizen Events
• Formal Kaizen Roles and Process

 

Module 5: Managing and Building Lean Teams

• Managing Teams
• Lean Teams
• Features of Lean Teams
• High Performing Teams (HPT)
• High Performance Challenge
• Contrasting Team Structures
• Managing Progress and Demonstrating Control
• Kanban Board
• MoSCoW Prioritisation
• Daily Stand-Ups
• Managing Teams
• Work Cells
• Lean Management
• Self-Managed Team Philosophy
• Lean Manager and the Self-Managed Team
• Personality Styles
• High Performing Teams (HPT)
• Autonomous HPTs
• High Performance Challenge

 

Module 6: Problem-Solving

• Problem Solving
• Problem Solving Framework
• A Seven-Step Problem-Solving Methodology
• Prioritisation Tools
  • Pay-off matrices
  • Weighting through voting
  • Weighting with evaluation criteria
  • Pugh Matrix

 

Module 7: Visual Management

• Introduction to Visual Management
• Guidelines for Visual Management

 

Module 8: Advanced VOC

• Advanced Intelligence Methods
• Ways of Gathering the VOC
• Intelligence Gathering: Top Tips
• Critical to Quality Trees
  • Steps to Creating a CTQ Tree

 

Module 9: Lean Metrics

• Metrics
• Measures and Targets
• A Reminder: Fundamental Lean Metrics
• Metrics Drive Behaviour
• Traditional Vs Lean Metrics
• Choosing the Right Metrics
• Things to Consider When Selecting Metrics
• Useful Metrics
• First and Second Project Metrics
• Metrics and Measures Roadmap

 

Module 10: Process Measurement

• What are Lean Process Measurements?
• Two-Level Measures
• Four Sub-Metrics
• Availability
• Quality
• Performance
• Loading
• Calculating OEE and TEPP
• OEE is Not a Magic Number
• First Time Quality
• Rolled Throughput Yield (RTY)
• Work in Progress
• Completed Orders Metrics
• Delivery Metrics
• Warranty Metrics
• Customer Feedback Metrics
• Reporting Metrics
• Aims of Data Collection
• Key Performance Indicators
• Process Measurement Points
• List of Criteria for a Good Measure
• Gauge R and R
• Measurement System Resolution
• Brief Description of Data Collection Planning
• Five Steps of the Data Collection Process
• Data Collection Sheet
• Frequency and Sample Size
• Evolving Your Data Collection Plan

 

Module 11: Total Productive Maintenance

• TPM in a Nutshell
• What is TPM?
• TPM: Goals
• Why is TPM Needed?
• Benefits of TPM
• TPM: What to Focus On?
• TPM: Where Should it be Applied?
• TPM Maturity Levels
• TPM Health Check
• Implementation Structure of TPM
• Establish Infrastructure
• Eliminate Top Issues
• Training
• Conduct Autonomous
• Conduct Planned Maintenance
• Design Maintenance Prevention

 

Module 12: Process Levelling (Heijunka)

• Heijunka
• Heijunka in a Nutshell
• Process Levelling Overview
• Production Levelling
• Demand Levelling
• Sequencing
• Sequencing Concepts
• Single Piece Flow
• First in First Out
• Pull
• Kanban
• Three-Bin System
• Kanban Operation Rules
• Andon
• Process Levelling
• Resource Scheduling
• Theory of Constraints
• TOC Process
• Other Techniques to Enable Level Scheduling
• Process Levelling in the Office
• What is the Minimum Cycle Time for a Form?
• Putting it All Together
• Lean Office: How it Was?
• Purchasing Department: After Laen
• The Lean Office: Putting it All Together

 

Module 13: Value Stream Mapping

• Value Stream Terminology
• Process Maps
• Swim Lanes
• Typical Process Map Contests
• Value Stream Maps
• Headache Tablets: Value Stream Mapping
• Process Maps
• Process Map Levels
• On the Ground Instructions (OTGIs)
• What is a Value Stream?
• Creating the “As Is” VSM
• Investigating and Understanding the Process
• Headache Tablets: Value Stream Mapping
• Creating a VSM: Process Borders Definition
• Process Boxes
• Useful VSM Metrics
• Square Wave
• Creating an Improved Process
• Steps for Building a Value Stream Map
• Action Plans
• Identifying Priorities: Effort/Impact Grid

 

Who Should Attend:

This Training Course is designed to provide delegates with a comprehensive understanding of Lean principles and methodologies. The Course is beneficial for the following professionals:

• Project Managers
• Lean Practitioners
• Senior Managers
• Frontline Employees
• Operational Staff
• Quality Control Professionals
• Supply Chain and Logistics Personnel

 

Training Methodology

• Online Instructor-led
• Online Self-paced
• Classroom Onsite

 

Certificate

• On successful completion of this training course, the ALARDI Africa Certificate will be issued to the participants.

 

Certificate: Upon completion of the course the participants will be issued with the ALARDI Africa Certificate.

Venue: Virtual Course Delivered on Registration

Cost: USD 1440

Date: All year round/Pax can register any time.