Lean Foundations

Summary

This course provides a clear, practical introduction to Lean thinking for engineers and technical professionals who are new to continuous improvement. Participants learn how Lean improves flow, reduces waste, and supports better decision-making across engineering and operational processes.

Through realistic examples and an interactive simulation, the course builds Lean awareness and systems thinking without requiring prior experience or authority to implement change.

How will I benefit?

After the course you will be able to:

  • Recognise where delays, rework and waste occur in operational processes
  • Understand how flow, workload balance and customer demand affect overall system performance
  • Ask better questions about how work is organised and where improvements are possible
  • Contribute more effectively to Lean or improvement initiatives led by others
  • Identify practical opportunities to simplify processes and reduce unnecessary activity
  • Understand how Lean thinking connects operational performance, teamwork and continuous improvement

Who should attend?

This course is suitable for engineers at all levels who wish to understand the fundamentals of Lean, including:

  • Graduates and Apprentices looking to build a strong foundation in Lean Thinking and Continuous Improvement
  • Engineers, technicians and specialists contributing to operational excellence
  • Technical professionals who want to better understand Lean concepts, terminology and practices used within their organisation
  • Team Leaders and supervisors responsible for improving team performance, productivity and day to day operations
  • Supply chain, logistics and services delivery teams aiming to improve workflow, responsiveness and customer value

Course Outline / Key Topics

Introduction to LEAN

  • Why do organisations struggle with delays, rework, firefighting, overburdened people?
  • Origins of Lean
  • Principles of Lean
  • Lean as a system, not a toolbox
  • Local optimisation vs system optimisation

Lean Simulation

Understanding and Mapping Work

  • Voice of the Customer
  • Understanding a process
  • High level Process Mapping
  • Value add / non-value add
  • The 8 wastes (“Muda”)

Pull and One-piece flow

  • One-piece flow, Kanbans

Line Balancing

  • Takt Time / Cycle Time
  • Balance the workload to meet customer demand

What Lean looks like in Practice

  • Case examples and discussions

Reflection and Transfer

  • Where do I see waste or flow issues?
  • What questions should I now be asking at work?
  • What would a ‘better system’ look like?