Lean Management Fundamentals

Programme Summary

This programme helps supervisors and improvement teams apply Lean thinking to everyday operational problems. Participants examine customer value, workflow, workplace organisation and practical Kaizen using a realistic process case. Structured activities connect 5S, visual management and standard work with measurable improvement, enabling teams to organise a focused intervention and sustain useful changes through employee involvement and regular performance review.

Training Objectives

1 Connect Lean thinking with customer value; 2 Strengthen identification of waste and flow problems; 3 Develop practical workplace organisation and visual management; 4 Build disciplined Kaizen and improvement-team participation; 5 Plan standardisation and sustained performance review.

Learning Outcomes

1 Identify waste within a defined process; 2 Map current flow and improvement opportunities; 3 Develop a practical five-stage 5S plan; 4 Prepare a focused Kaizen experiment and measures; 5 Specify standard work and sustaining review arrangements.

Target Audience

Production Supervisors; Team Leaders; Continuous Improvement Coordinators; Warehouse Supervisors; Operations Managers; Administrative Process Owners.

Target Industries

Manufacturing; Food Processing; Warehousing; Healthcare Administration; Construction Support Services; Shared Services.

Course Contents

• Module 1 Lean Purpose and Customer Value: Customer value and process purpose; Respect for people and practical learning; Waste unevenness and overburden.
• Module 2 Understanding Current Process Flow: Process observation and factual baselines; Flow mapping and handover delays; Bottlenecks queues and unnecessary movement.
• Module 3 Workplace Organisation through 5S: Sort and set-in-order decisions; Cleaning inspection and abnormality visibility; Standardisation and sustained workplace discipline.
• Module 4 Visual Management and Standard Work: Visual signals and abnormality recognition; Work sequence timing and clear responsibilities; Practical standards and operator involvement.
• Module 5 Kaizen and Structured Experimentation: Selecting a bounded improvement opportunity; PDCA hypothesis measures and trial design; Learning from results and unintended effects.
• Module 6 Practical Flow Improvement Methods: Simplifying steps and reducing changeover losses; Pull signals and inventory visibility; Mistake-proofing and task balancing principles.
• Module 7 Team Participation and Daily Management: Employee ideas and respectful problem discussion; Short review routines and action follow-up; Escalating barriers and supporting ownership.
• Module 8 Lean Improvement Case Workshop: Develop a focused workplace improvement plan; Specify results measures and trial conditions; Plan handover standardisation and sustaining reviews.

Assessment

• 40 single best answer questions, including applied scenarios; one mark per question.
• 60 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Supplied Lean tool templates permitted; internet, messaging and AI tools prohibited.
• Individual applied assessment (30 minutes): Using a supplied process and workplace case, identify priority waste, produce a targeted 5S plan and design a Kaizen trial with a baseline, measurable expected result and sustaining standard.
• Assessment criteria: Accurate identification of waste and underlying process constraints; Practical employee-centred 5S and Kaizen actions; Clear trial measures and sustaining ownership.
• Pass each component separately: 30/40 written marks (75%) and at least 70% on the applied task.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records assessed Lean fundamentals and improvement planning skills; workplace implementation and independent practitioner certification require separate evidence.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

222

Total teaching hoursTotal teaching hoursTotal teaching hours

12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 20 delegates.Maximum 20 delegates.Maximum 20 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

No formal qualification required. Familiarity with an operational or administrative process is recommended.No formal qualification required. Familiarity with an operational or administrative process is recommended.No formal qualification required. Familiarity with an operational or administrative process is recommended.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Spend 20 minutes reviewing the supplied workplace photographs and process map, noting delays, excess movement and unclear storage arrangements.Spend 20 minutes reviewing the supplied workplace photographs and process map, noting delays, excess movement and unclear storage arrangements.Spend 20 minutes reviewing the supplied workplace photographs and process map, noting delays, excess movement and unclear storage arrangements.

End of course assessmentEnd of course assessmentEnd of course assessment

40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance.75% written and 70% applied, passed separately; full attendance.75% written and 70% applied, passed separately; full attendance.