Lean Practitioner

Lean Practitioner – overview

This course helps participants develop an in-depth Lean Practitioners’ skill set. The Lean Practitioner, a key role in many companies, is fully equipped to return to their organisation and make a real measurable difference (both to the customer and to the company’s balance sheet).

Full details below or download course outline.

Learning objectives

At the end of the course each participant will have a detailed theoretical knowledge of the key Lean tools. More importantly, they will have had the chance to see how the techniques work practically and in combination with each other.

As qualified Lean Practitioners, participants will leave the programme able to:

  • Understand how the ‘lean toolbox’ can benefit any organisation and generate improvements and substantive gains in efficiency and quality through the use of appropriate lean techniques
  • Identify and minimise waste and non-value added activity throughout an organisation’s processes
  • Play a role in developing appropriate scorecards and improvement techniques within an organisation
  • Involve people at all levels in problem solving/process improvement activities in a fulfilling and motivational way
  • Complement, broaden and enhance current improvement activities (including the use of Six Sigma)

Most importantly, they will be able to begin the ‘lean journey’ in their own organisation.

Who should attend?

All managers and anyone involved in the business improvement structure related to the development and improvement of the business.

Course format

This highly participatory four-day workshop programme includes extensive practical analysis exercises and all participants will be involved in extensive team work.

Relevant case studies will be used throughout the programme and participants will be expected to bring examples of customer analysis from their own organisation.

Given the practical nature of this workshop-style programme, there is a maximum limit of twelve participants (minimum four).

Special feature

A one-day introductory version of this programme is available on request.

Introduction to Minitab – course outline


1 Introduction

  • History and philosophy of Lean
  • Principles and practice of Lean

2 Lean implementation

  • Initial benefits
  • An initiator of change
  • Workshop 1: Lean implementation
  • Workshop feedback

3 Introducing MUDA and the seven wastes

  • Muda
  • The seven wastes
    • – Transport
    • – Inventory
    • – Motion
    • – Waiting
    • – Over-production
    • – Over-processing
    • – Defects

4 Workshop case study

  • The Big Efficient Card Company – Part 1
  • Feedback and debrief

5 Workplace organisation and visual management techniques

  • Exercise – Communicating meaning


1 The PDCA process

  • Plan
  • Do
  • Check
  • Act

2 8D approach to problem-solving

  • Plan
  • D1 – Form a team
  • D2 – Describe the problem
  • D3 – Develop interim containment plan
  • D4 – Determine root causes
  • D5 – Verify permanent corrections
  • D6 – Implement corrections
  • D7 – Prevent it happening again / elsewhere
  • D8 – Celebrate success

3 Six Sigma and DMAIC

  • The DMAIC roadmap
    • – Define
    • – Measure
    • – Analyse
    • – Improve
    • – Control

4 5S and visual management

  • The 5S approach
    • – Sort
    • – Streamline
    • – Shine
    • – Standardise
    • – Sustain
    • 5S tools and techniques

5 Workshop case study

  • The Big Efficient Card Company – Part 2
  • Feedback and debrief

6 Lean measures and metrics


1 Process mapping

  • Key techniques
  • How to use them

2 Value stream mapping

  • Current state mapping
  • Future state mapping

3 Workshop case study

  • The Big Efficient Card Company – Part 3
  • Feedback and debrief

4 Total productive maintenance (TPM)


1 Rapid change-over techniques (SMED)

2 Flexible systems design

  • The Kanban approach

3 Lean supply chains

  • The total value chain approach

4 Workshop case study

  • The Big Efficient Card Company – Part 4
  • Feedback and debrief
  • Lean implementation case study: Bringing it all together