Lean Process Improvement Fundamentals

Module 1: Lean principles in plain language

• Why Lean and how it helps people, customers, and results
• Value, flow, pull, and the idea of continuous improvement
• The seven wastes and simple examples in office and operations
• Ground rules for respectful improvement and change

Module 2: See the process end to end

• Scope a process with purpose, start, end, and customers
• Basic flow map and swimlanes for roles and handoffs
• Quick tips for clear labels, flow direction, and layout
• Find queues, rework, and unclear decisions on the map

Module 3: Measure what matters

• Lead time, touch time, first pass yield, and simple counts
• Collect facts with ticksheets and basic samples
• Separate signal from noise with simple run charts
• Choose a few measures that match the goal

Module 4: Stabilize with standards and visual management

• Standard work at a beginner level steps, sequence, timing
• Visual controls checklists, boards, and simple status signals
• Basics of 5S sort, set, shine, standardize, sustain
• Make it easy to see normal vs abnormal

Module 5: Problem solving and root cause

• Clarify the problem and the current condition
• 5 Whys and simple cause and effect diagrams
• Define a target condition and small countermeasures
• Basic A3 thinking and short learning loops

Module 6: Prioritize and test changes

• Impact vs effort matrix and quick win filters
• Simple experiment design with who, what, when, and check
• Avoid common pitfalls scope creep and overengineering
• Capture lessons learned and decide next steps

Module 7: Value stream view and flow improvements

• From a single process to a simple value stream snapshot
• Remove delays, reduce handoffs, and balance work
• Pull signals at a beginner level task readiness and limits
• Align improvements with customer outcomes

Module 8: Sustain and build a culture of improvement

• Daily and weekly routines standups and quick checks
• Visual metrics and short reviews that drive action
• Roles for sponsors, leads, and teams
• Ninety day plan and a small improvement backlog