(A) Lean manufacturing principles

  1. Lean manufacturing principles: Introduction
  2. Lean ideology- the idea of Lean in terms of value creation.
  3. Waste (MUDA)
  4. Major types of non-value adding waste in business
  5. Seven kinds of Waste (MUDA)
  6. Four approach to waste elimination in an organization
  7. The focus of Lean management principles – five focus of Lean management
  8. Six objectives of Lean management
  9. Lean management tools :
    • Histogram
    • Quality control card
    • Pareto diagram
    • Correlation diagram
    • Brainstorming techniques
    • Ishikawa diagram (fishbone analysis)

Lean management tools : explanation

  1. Histogram
  • Introduction of Histogram
  • Importance of Histogram, usefulness of histogram
  • Graphical representation of histogram and its explanation.
  1. Pareto diagram
  • Introduction of Pareto diagram
  • Importance of Pareto chart
  • Usefulness of Pareto chart
  • Graphical representation of Pareto charts and its explanation
  1. Scatter diagram
  • Introduction of Scatter diagram
  • Importance of Scatter diagram
  • Usefullness of Scatter diagram
  • Graphical representation of Scatter diagram and its explanation.
  1. Brainstorming techniques
  • Introduction of brainstorming techniques
  • Advantage of brainstorming techniques
  • Brainstorming techniques process
  • Types of brainstorming techniques
  • How to carry out brainstorming study
  1. Cause and effect diagram
  • Introduction of cause and effect diagram
  • Importance of cause and effect diagram
  • Usefulness of cause and effect diagram
  • Graphical representation of cause and effect diagram and its explanation

10. General Lean Management tools

  • List of general lean management tools we can come across in practice.

11. Lean methods: identify and explanation

  • Lean management and Kaizen
  • Lean management and Total productive maintenance TPM
  • Lean management and the Pull principles
  • Lean management and Visual management
  • Lean management and Poka-yoke

12. Lean Development

13. Some practical Lean foundation tools:

  • Kaizen, PDCA, JIDOKA, Poka-Yoke standardized work, Kanban, Genchi Genbutsu
  • 5S principles
  • Operating equipment effectiveness (OEE) measurement and development.

14. Development of machine efficiency in Lean management:

  • Total productive maintenance TPM
  • Single minutes exchange of dies-SMED principle
  • Operating equipment effectiveness (OEE) measurement and development

15. Material flow development and desing manufacturing cells:

  • Just-In-Time (JIT) principles (i.e. Pull system and talk-time explanation)
  • Cell based production
  • Push system
  • Pull system

(B) 5 Why Analysis

  • Meaning of 5 Why Analysis
  • Cause investigation steps using 5 Why analysis
  • 5 Why analysis practical problem solving methodology in details.

(C) Check sheet: Tools for generating information

  • Meaning of check sheet, what is it?
  • When to use check sheet
  • How to use check sheet
  • Grephical representation of check sheet.

(D) Flow charts: Tools for organizing information

  • Meaning of flow chart
  • When to use flow chart
  • How to use flow chart
  • Graphical representation of flow chart

(E) Kaizen principles

  • Meaning of Kaizen principles
  • Attributes of Kaizen principles
  • Kaizen objectives
  • Kaizen benefits
  • Application of Kaizen implementation in the organization.
  • Approaches for Kaizen implementation in the organization.
    1. 5S principles
    2. 8D methodology
    3. Value stream mapping (VSM)
    4. PDCA cycle


  1. 5S principles: meaning of 5S principles, 5S acronym i.e. sort, set, shine, standardize.
  2. 8D methodology: meaning of 8D methodology, forming of cross functional team in 8D methodology, Summary of the 8D process.
  3. Value stream mapping: meaning of VSM, Usefulness of VSM, Basic steps in VSM, Graphical representation of VSM.
  4. PDCA Cycle: meaning of PDCA cycle, when to use PDCA cycle, PDCA cycle-Graphical representation, PDCA cycle-explanation.

(F) Poka-Yoke (Mistake proofing)

  • Meaning of Poka-Yoke
  • Example of Poka-Yoke
  • Application of Poka-Yoke device
  • Importance of Poka-Yoke device

(G) Statistical Process Control (SPC)

  • Meaning of SPC philosophy, application of SPC principles, and its originator.
  • Control Charts – meaning of control chart, focus on variations.
  • How do control chart help to avoid defects
  • Brief history of Control chart
  • Cause of Variation: Common cause of variation & Special cause of variation
  • Statistical Process Control –SPC- test vales. Graphical representation of the test values.
  • Steps in constructing an Average and Range chart (X-bar and R):
  1. Select the process characteristics
  2. Establish the sampling plan and rational subgroup size
  3. Gather data/Enter into Minitab software
  4. Establish the overall mean and control limits
  • Control Limits calculation for each type of control chart.