Lean Manufacturing Training Modules

TDO offers training in all of the Lean Manufacturing tools and techniques. Programs include:

Lean Overview (Lean 101) - Factory version   read »
Lean Overview (Lean 101) - Office version  read »
5S  read »
Cellular Design  read »
Kaizen read »
Quick Changeover (SMED)  read »
Pull/Kanban Systems  read »
Total Productive Maintenance  read »
Value Stream Mapping (VSM)  read »
Visual Controls  read »

 Lean Overview (Lean 101) - Factory version

This eight-hour workshop introduces the basic concepts of lean manufacturing and demonstrates the tools and methodologies necessary to implement "lean" on the shop floor. It combines comprehensive classroom presentations with hands-on simulation of a production facility. The live simulation uses a powerful "train-do" technique incorporating four production shifts to illustrate cause and effect relationships for each of the lean tools presented. Participants review methodologies and lessons while working with realistic constraints such as limited available resources, restricted cash flow and resistance to change.

Participants will gain an understanding of the eight wastes in manufacturing and learn how to improve productivity by applying standard work, visual controls, set-up reduction, batch size reduction, point-of-use storage, quality at the source, pull systems, Kanban, cellular flow and more.

 Lean Overview (Lean 101) - Office

Lean Principles, focusing on value-added activities and eliminating needless tasks, have as much relevance in the office as on the manufacturing floor. There are many benefits to adopting a lean culture in the office including reduced costs, faster processing times, less duplicate work, improved quality, and better customer satisfaction.

This full-day workshop provides an overview of lean concepts and their application to office and administrative processes. Participants will learn to use various lean concepts in an interactive and dynamic simulation, eliminating wastes and achieving better information flow. This train-do technique over three "shifts" illustrates cause and effect relationships for each of the lean tools presented. As part of the simulation, participants will also gain experience in an office kaizen event. Most importantly, the participants will be able to measure the impact of their improvement efforts.


Participants learn the concepts of the 5S System and then apply them to transform a cluttered, disorganized area into a clean, organized and orderly workplace. The course offers an opportunity to experience first hand how the 5S system reduces waste and improves productivity and quality in a simulated production facility. Participants will learn to describe the difference in workplace appearance and functionality before and after the 5S process has been applied. Participants perform an in-depth audit of workplace organization and standardization; organize a workplace by applying the concepts of sort, set-in order and shine; standardize procedures to maintain and control an organized workplace using visual controls; and describe how 5S can help to improve workplace environmental health and safety.

 Cellular Design

In this course, participants will recieve training on the principles of Cellular Flow Manufacturing and the class will apply the learned principles to a specified production line in the company. Our team will lead participants through the 5-step process for designing and implementing work cells for their company. This process applies to both assembly and machining apllications. This workshop will demonstrate how to link and balance manufacturing operations to reduce lead time, minimize work in progess, optimize floor space usage, and improve productivity.


A Kaizen event is a hands-on series of activities following a the structured Shingijutso method of Documenting Reality, Identifying Wastes, Planning Countermeasures, Implementing Changes, Verify Changes, Quantify Results and Make Standard. This cycle will be taught and facilitated on a targeted area as defined with the Value Stream Mapping reinforcing the training delivered in that module. The Lean tools of Kanban, Flow, Error proofing, and Hanedashi will be used in hands on activities that will reinforce the Lean 101 workshop and facilitate the staff to continually improve their process using the lean tools.

  Pull/Kanban Systems

This workshop will define a six-step methodology to implement Pull/Kanban Material Systems. In addition, attendees will see the concepts in practice in repetitive and non-repetitive, as well as seasonal demand applications. Attendees will learn to set-up point-of-use material storage, interface pull systems with existing planning systems, and set lot sizes based on capacity, not economic order quantity theory. Participants will experience firsthand the benefits of implementing Pull/Kanban systems, which include simplified processes, fewer stock-outs, less inventory, lower space requirements, higher productivity and greater flexibility in a specific area of the business.

 Quick Changeover (SUR/SMED)

This workshop will teach the principles of Quick Changeover, otherwise known as Set-Up Reduction (SUR) and Single Minute Exchange of Dies (SMED). The changeover improvement process will be applied to achieve set-up reduction in an exercise. By the end of the session you'll experience reduced costs and setup times and see machine capacity increase at the same time.

 Total Productive Maintenance 

Learn about Overall Equipment Effectiveness (OEE) and how it is related to capacity. The ten-fold effect of 5S techniques when applied to your equipment. The six major equipment-related losses, how to find and eliminate 4 of the causes of 75% of equipment breakdowns. Participants will apply the techniques on our simulated equipment in the classroom. By the end of the session, you'll experience how these techniques achieve dramatic improvements in uptime and increased equipment effectiveness.

 Value Stream Mapping (VSM)

Value Stream Mapping (VSM) is used to create a material and information flow map of production processes and the relationship between various levels in a multi-tiered suppy chain. Participants learn to: Map material, information, and supply chain flows Map current and future states; participate in a simulation; Present fundamental concepts of visual schematic diagramming devices; Provide practical, real-world applications for the course content; Facilitate the process of identifying systemic waste in order to visualize a waste-free future state; Prepare for Kaizen events. 

 Visual Controls

This seminar provides a conceptual understanding of the visual workplace as well as an overview of the methodology for implementing and sustaining visuality throughout the enterprise. The seminar properly positions the technologies of the visual workplace - as a powerful partner to a company's journey to excellence and crucial to its ability to maximize lean results. With visual order (5S) in place, an organization is then ready to move on to more advanced visual applications: visual standards, visual displays, visual metrics, and beyond. Learn about the crucial link between visual and lean. Attendees will explore examples of visual solutions from workplaces.


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This printout was brought to you by the Central New York Technology Development Organization.