Lean Management | Certified Lean Expert (Accredited) Course Syllabus

Overview: This comprehensive Lean Management course is designed to equip professionals with the knowledge and tools to lead continuous improvement initiatives and drive operational excellence. Through a blend of theoretical concepts, real-world case studies, and practical applications, learners will progress through eight structured modules totaling approximately 6 hours of content. The course prepares participants for Lean certification (P2 level), emphasizing hands-on techniques like Value Stream Mapping, A3 problem-solving, and Kaizen leadership. With lifetime access, the program is ideal for individuals aiming to lead lean transformations across manufacturing, healthcare, logistics, and service sectors.

Module 1: Lean Thinking & Value Stream Mapping

Estimated time: 0.75 hours

• Understanding lean principles: value vs. waste identification
• Defining value from the customer's perspective
• Mapping current state value streams
• Designing future state value streams for improved flow

Module 2: Flow, Pull & Takt Time

Estimated time: 1 hour

• Establishing continuous flow in processes
• Calculating takt time to align with customer demand
• Designing pull systems using Kanban boards
• Implementing supermarket models for inventory control

Module 3: Heijunka & Visual Management

Estimated time: 0.75 hours

• Applying heijunka (production leveling) to reduce batching
• Smoothing workload variations across operations
• Implementing visual controls: Andon systems and scoreboards
• Using process dashboards for real-time performance tracking

Module 4: Kaizen & A3 Problem Solving

Estimated time: 1 hour

• Planning and executing kaizen events
• Documenting improvements and sustainment strategies
• Applying the A3 problem-solving template
• Conducting root cause analysis and developing countermeasures

Module 5: Lean Metrics & Performance Measurement

Estimated time: 0.75 hours

• Measuring Overall Equipment Effectiveness (OEE)
• Tracking first-pass yield and process cycle times
• Monitoring lead time and other KPIs
• Data collection and analysis for decision-making

Module 6: Leadership & Daily Management

Estimated time: 0.75 hours

• Establishing standard work for leaders
• Conducting daily huddles and tiered accountability meetings
• Implementing coaching cycles for continuous improvement

Module 7: Lean Transformation Roadmap

Estimated time: 0.75 hours

• Developing a phased lean rollout plan
• Engaging stakeholders and managing change
• Assessing risks and implementing mitigation strategies

Module 8: Certification Prep & Case Studies

Estimated time: 0.5 hours

• Reviewing sample certification exam questions
• Studying lean certification criteria and best practices
• Analyzing real-world case studies of successful lean implementations

Prerequisites

• Familiarity with basic business processes
• Interest in continuous improvement or operational efficiency
• No prior lean experience required

What You'll Be Able to Do After

• Map and optimize value streams using industry-standard tools
• Design and implement pull systems and visual management controls
• Lead kaizen events and apply A3 problem-solving effectively
• Measure and improve key lean performance metrics like OEE and takt time
• Develop and execute a sustainable lean transformation strategy