LEAN MANUFACTURING FUNDAMENTALS
Driving Operational Excellence Through Waste Reduction and Process Optimization
Course Schedule
| Date | Venue | Fees |
|---|---|---|
| 09 – 13 Feb 2026 | Dubai, UAE | USD 3495 per delegate |
Course Introduction
In today’s highly competitive manufacturing environment, organizations must continually improve efficiency, reduce waste, and enhance value delivery to remain profitable. Lean Manufacturing offers a proven methodology for streamlining operations, improving quality, and maximizing customer satisfaction through systematic waste elimination.
This intensive 5-day course provides a solid foundation in Lean principles, tools, and techniques, enabling participants to identify non-value-added activities, optimize workflow, and foster a culture of continuous improvement. Through case studies, interactive sessions, and practical exercises, attendees will gain the knowledge and skills necessary to lead Lean initiatives within their organizations.
Course Objectives
By the end of this course, participants will be able to:
• Understand the core principles and philosophy of Lean Manufacturing
• Identify and eliminate the 8 types of waste in manufacturing environments
• Apply key Lean tools such as 5S, Kaizen, Value Stream Mapping, and Kanban
• Improve flow, reduce cycle time, and enhance productivity
• Support the development of a continuous improvement culture on the shop floor
Key Benefits of Attending
• Build a strong foundation in Lean tools and methodologies
• Drive operational efficiency and waste reduction
• Learn from industry-based case studies and proven Lean transformations
• Equip yourself to lead or support Lean implementation initiatives
• Receive practical tools and templates for Lean deployment
Intended Audience
This program is designed for:
• Manufacturing supervisors and operations managers
• Process improvement professionals and Lean coordinators
• Quality and production engineers
• Industrial engineers and supply chain staff
• Anyone involved in manufacturing or operational excellence
Individual Benefits
Key competencies that will be developed include:
• Strong grasp of Lean Manufacturing principles
• Practical ability to map processes and identify inefficiencies
• Skill in applying 5S, Kaizen, and standardization tools
• Leadership in Lean team initiatives and improvement projects
• Enhanced problem-solving and root cause analysis techniques
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Reduced production waste and improved resource utilization
• Improved process reliability and operational control
• Faster turnaround times and improved customer satisfaction
• Better employee engagement through involvement in Lean projects
• A scalable foundation for continuous improvement culture
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Strategy Briefings – Lean philosophy, principles, and value stream concepts
• Case Studies – Success stories of Lean transformation in global industries
• Workshops – Hands-on simulations and process improvement exercises
• Peer Exchange – Group discussions on Lean challenges and success strategies
• Tools – Value stream mapping templates, 5S checklists, and waste identification guides
Course Outline
DETAILED 5-DAY COURSE OUTLINE
Training Hours: 07:30 AM – 03:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Lean Foundations and Waste Elimination
- Module 1: Introduction to Lean Thinking (07:30 – 09:30)
• History and evolution of Lean Manufacturing
• Principles of Lean: value, value stream, flow, pull, perfection
• Understanding value-added vs. non-value-added activities - Module 2: Identifying the 8 Wastes (09:45 – 11:15)
• Detailed exploration of the 8 types of waste (TIMWOODS)
• Real-world examples of waste in manufacturing processes
• Techniques to identify and classify waste - Module 3: Creating a Lean Mindset (11:30 – 01:00)
• The role of leadership and culture in Lean success
• Engaging teams in continuous improvement
• Overcoming resistance to Lean adoption - Module 4: Lean Simulation Exercise (02:00 – 03:30)
• Hands-on simulation of a wasteful process
• Team analysis and recommendations
• Group discussion and debrief
Day 2: 5S and Standard Work
- Module 1: Implementing 5S for Workplace Organization (07:30 – 09:30)
• Overview of Sort, Set in Order, Shine, Standardize, Sustain
• Benefits and visual management techniques
• 5S audit methods and templates - Module 2: Standard Work and Visual Controls (09:45 – 11:15)
• Defining and documenting standard operating procedures
• Balancing operator workloads and cycle times
• Visual controls to enhance productivity and quality - Module 3: Workplace Improvement Workshop (11:30 – 01:00)
• 5S assessment of a mock or real workplace
• Identification of opportunities for standardization
• Group presentations and feedback - Module 4: Kaizen Principles and Event Planning (02:00 – 03:30)
• Philosophy of Kaizen and small-step improvements
• Planning and executing a Kaizen blitz
• Monitoring results and sustaining change
Day 3: Value Stream Mapping and Flow Optimization
- Module 1: Introduction to Value Stream Mapping (07:30 – 09:30)
• Understanding the current and future state value streams
• Mapping material and information flow
• Identifying bottlenecks and delays - Module 2: Improving Process Flow (09:45 – 11:15)
• Principles of one-piece flow and takt time
• Creating balanced and synchronized operations
• Line layout improvements and cellular manufacturing - Module 3: Pull Systems and Kanban (11:30 – 01:00)
• Concepts of pull production and inventory control
• Implementing and managing a Kanban system
• Avoiding overproduction and managing replenishment - Module 4: Waste Reduction Project Planning (02:00 – 03:30)
• Selecting a pilot area for Lean implementation
• Defining goals, metrics, and action plans
• Team assignments and accountability
Day 4: Lean Tools and Quality Integration
- Module 1: Root Cause Analysis and Problem Solving (07:30 – 09:30)
• The 5 Whys, Fishbone Diagram, and Pareto Analysis
• Defining problems and tracing back to root causes
• Preventive actions and corrective response - Module 2: Mistake-Proofing (Poka-Yoke) (09:45 – 11:15)
• Strategies for designing out human error
• Examples of mistake-proofing devices and systems
• Linking Poka-Yoke to quality and safety - Module 3: Integrating Lean with Quality Tools (11:30 – 01:00)
• Synergies between Lean, Six Sigma, and TQM
• Quality at the source and error detection
• Lean metrics and performance indicators - Module 4: Mid-Course Progress Review (02:00 – 03:30)
• Group reflections and learning checks
• Challenges encountered and lessons learned
• Q&A with the trainer
Day 5: Sustaining Lean and Driving Culture Change
- Module 1: Leadership Role in Lean (07:30 – 09:30)
• Coaching teams and leading by example
• Gemba walks and visual leadership
• Building accountability at every level - Module 2: Lean Implementation Roadmap (09:45 – 11:15)
• Phases of Lean deployment
• Setting targets and tracking progress
• Common pitfalls and success enablers - Module 3: Final Workshop – Lean Project Design (11:30 – 01:00)
• Teams develop a Lean project proposal
• Presentation of ideas and peer feedback
• Trainer recommendations for rollout - Module 4: Final Assessment and Course Wrap-Up (02:00 – 03:30)
• Post-course evaluation and knowledge check
• Review of personal action plans
• Certification ceremony and feedback
Certification
Participants will receive a Certificate of Completion in Lean Manufacturing Fundamentals, verifying their ability to apply Lean principles, tools, and techniques to reduce waste, streamline operations, and drive sustainable performance improvements in manufacturing environments.