Our Lean Foundation course modules also form part of the overall Lean Six Sigma Yellow Belt, Green Belt and Black Belt courses.

Why choose us?

  • We use the full, undiluted Lean and Six Sigma Curriculum
  • Our exams are secured to the ISO 13053 part 1 & 2 Standard
  • If you are not satisfied with our SCORM accredited online training, we will give you your money back plus 10% extra - guaranteed!

Online, In Public, In-House

  • Who is it for?

    Lean manufacturing list of benefits

    The Zenith Lean Foundation Course is a must for all employees to enable them to understand why Lean improvements are required within their organisationand is available as a public training course or online (e-learning).

    The Lean Foundation course helps people understand the changes that are required and why Lean is necessary for the transition to world class performance. Office workers, production operators and supervisory staff often feel they are not being communicated to, therefore they feel disengaged from the strategic intent of senior management.

    In many organisations, the argument for this transition is not conveyed correctly, when in fact job security and better pay is often the result of a Lean intervention and it is no coincidence that world class organisations provide the best security and pay deals in their respective markets.

  • Course Syllabus

    Introduction and Lean Overview

    Training course syllabus
    • The History of Lean, it origins and how it came to the Western world
    • Lean/Continuous Improvement approach - Getting things right first time
    • Creativity using the skills of our staff to produce the ideas
    • Understanding the Five Principles of Lean (Value - Value Stream - Flow - Pull - Perfection)
    • The Eight Wastes TIM WOODS (Transport - Inventory - Motion - Waiting - Over-processing Overproduction - Defects - Skills)
    • The Eight Wastes in the office - how they differ
    • Basic problem solving (use of the five WHY’s when issues and problems affect a process)
    • Understanding the job roles of the: Lean Sponsor - Lean Champion - Lean Practitioner/Facilitator - The Team Leader and finally the Lean Team Member
    • One Piece Flow

    The Methods of Mapping

    • Process Mapping - Its purpose and the requirements for mapping
    • Types of mapping; Current, Ideal and Future State, how to develop them and the purpose behind them (visualisation of the process and importance of the data-boxes supporting the visual map) - identifying the steps in the process
    • Value Stream Map - Its difference from process mapping and the requirements for mapping the whole process
    • Data collection its purpose and why is should be as accurate as humanly possible
    • The use of data boxes containing - Flow and Touch times, % Yield, WIP, Value and Non Value step recognition and why they are important
    • The importance of collecting all the data and projecting it as a picture of what the actual process looks like

    The Methods of Lean Intervention

    Fishbone cause & effect diagram
    • VSA - Value Stream Analysis
    • 2P - Preparation Process
    • Fishbone - Cause and Effect (problem solving)
    • RIE - Rapid Improvement Events Workplace Design
    • Preparation Process (2P) - Preparation Planning process mapping
    • The Rapid Improvement Event (RIE) - Short hit team driven event to make changes within 4.5 days
    • Workplace Setup - Understanding of the requirement to establish a perfect operating unit or product driven process containing: One Piece Flow - Standard Work - Pull - 6S or 5S
    • Perfection - the need to keep driving change forward
    • Zenith Lean Daily Management System (ZLDMS)

    Other Basic Tools and Techniques

    • Use of Spaghetti Diagrams, Paper Doll analysis and Swim lanes
    • Pull vs. Push methodology, Level Pull
    • Designing possible ideal and realistic future states and making a work plan
    • Creating flow (flow of the customer order throughout the process) and Pull (delivery to customer order instead of Push)
    • Problem Solving, Route Cause Analysis, PDCA (Plan-Do-Check-Adjust), Visual and Performance Management, SIPOC and the Pareto methodology that includes the understanding of Runners, Repeaters and Strangers

    Lean Techniques

    Exercise, simulations, videos, quizes and games.

    Case Studies of Lean

    Review of Lean interventions in administrative, healthcare, governmental, service, manufacturing, supply chain, engineering, research & development.

  • Features

    Lean Foundation Training Course folder
    • Tutor support for online training
    • Free access for public training students
    • Multiple Choice Questions for continuous self assessment
    • SCORM accredited Learning Management System
    • Online, Tablet and Android device compatible
    • Downloadable Handouts:
      • Waste Questionnaire, waste Radar
      • 5S and 6S Auditing software!
      • Templates
  • Benefits to you for doing this course

    After completing the course, participants will be able to:

    Training benefits
    • Have a basic awareness of the concepts of the Lean Methodology
    • Identify and understand the use of the tools and techniques
    • Develop their skills and experience by being part of Lean event teams through the mentorship and guidance of Lean experts
    • Understand the benefits of Lean
    • Helps staff to identify why they are being asked to act on issues and problems
    • Enables understanding of the influences upon processes and why Continuous Improvement is necessary
    • Identifying process waste and explains why people are always ‘fire fighting’
    • Gives you the confidence and knowledge to reason when suggesting improvements
    • Gives you the knowledge to apply world class methods into your organisation and support Organisation wide strategy
    • Brings your expertise to the attention of decision makers
    • Mandatory requirement for promotion in many organisations
    • Will improve career prospects
    • Gives you the ‘edge’ over competition for job applications
  • Certification

    Lean Foundation Training Course Certificate from Zenith Lean Training

    On successful completion of the Lean Foundation course, you will receive through the post your certificate.

    You will receive a beautifully hand crafted certificate which is embossed by hand with a legal foil showing your certification.

  • 1