- Fast-paced and engaging content
- Professionally narrated training
- Closed captioning transcript for videos
- Evaluation quizzes and tests included
- Competitively unrivaled pricing
- Concise and time-saving training duration
- Lean Fundamentals Training Certificate upon completion of the course
- Ability to pursue the Lean Agent Certification
Delivered in partnership with Global Six Sigma USA LP
What is Lean Fundamentals Training?
Lean Fundamentals course introduces the principles of Lean and the overall importance of focusing on what adds value to the customer. This program provides you with methods to recognize wastes in processes as well as identify barriers to flow and implement pull in your current processes. You will learn about the 5 Lean principles, and how these steps can guide you through a complete transformation of your process that engages your employees and increases customer satisfaction.
There are no prerequisites for the Lean Fundamentals program. Lean Introduction concepts are covered during this training.
- Lean Introduction – Theory & Quiz
This section covers the history and background of Lean, starting with Henry Ford up through Toyota, including what it is and what it is not. You will learn about organizations that have successfully implemented Lean. We will discuss how Lean works in manufacturing and non-manufacturing environments, helping you see the hidden waste. You will also learn about the 5 lean principles of Value, Value Stream, Flow, Pull and Perfection. You will understand how variation and waste leads to process excellence, why improvement initiatives fail, and the House of Lean that describes the core Lean leadership principles needed for success. We will also discuss the importance of developing a learning organization, and watch a video of a morning meeting at FastCap.
- Principles of Lean and A3 Thinking – Theory & Quiz
This section reviews the 5 lean principles, and introduces the Lean Triad, called the 3 M’s (Muda, Mura, Muri). You will also learn about different problem solving processes like Plan-Do-Check-Act and the 8-Step Problem Solving Process. You will learn how to communicate and organize your problem solving progress onto one sheet of paper, called an A3.
- Kaizen – Theory & Quiz
This section introduces the Japanese word “kaizen” which means incremental and continuous improvement of our processes. Kaizen can be done in our own work areas to save ourselves time and effort, while improving the quality of our work. We introduce a methodology called Kaizen Blitz which can be performed with a small team to make dramatic improvements to a targeted process, and is highlighted with a video. We also explain the popular kaizen event format, which is a multi-day session that brings together a team of people across multiple process areas to streamline the entire system. We share a video of a value stream mapping event, which follows the kaizen event format. We end the session with a discussion on a Lean Project, which is used for larger improvements that can take 3-6 months to complete.
- Foundation of Lean: Waste – Downloadable Resource, Theory & Quiz
One of the first ways to improve your process is to notice and identify the 3 M’s (Muda, Muri and Mura). We start with Muda, learning the 8 different types of waste, summarized by the acronym DOWNTIME. We will explain each of the 8 wastes, and give examples across multiple industries and sectors. We go through the other two M’s (Muri and Mura) and end with a video exercise of someone making toast, where you can practice spotting waste in the process.
- Lean Case Studies – Theory & Quiz
This section covers a few case studies across different sectors. We’ll take a look at the Province of Saskatchewan and how Lean applies to a government agency. Then we’ll look at a nonprofit, Saint Bernard Project, and how they used Lean to rebuild more homes. Next, we’ll look at Pierson Workholding, a small CNC manufacturer, to learn how they adopted Lean into their processes. Finally, we’ll look at the health care industry at the Virginia Mason Institute, an early adopter of Lean.
- 5S Workplace Organization – Theory & Quiz
5S is an improvement methodology used early in process improvement to establish better organization, better visual management and structure. It represents 5 steps that start with S: Sort, Set in Order, Shine, Standardization and Sustain. We walk you through each of the steps, discuss keys to a successful 5S implementation, watch a summary video from a healthcare clinic, and walk through a numbers game that reinforce the 5S principles.
- Define Value – Theory & Quiz
In order to determine what improvements we want to make, we must ensure we understand who our internal and external customers are, and what they value. This module will introduce methods for gathering the Voice of the Customer (VOC), comparing it to the Voice of the Business (VOB), and aligning it to True North. We will also explain how to use Lean to increase profits through cost reductions, not price increases.
- Lean Principle – Mapping the Process – Theory & Quiz
One of the first major steps in improving a process is to understand the current process in great detail. We can capture the current state using various types of process maps, such as a SIPOC diagram, flow charts, swim lane maps, spaghetti diagrams and value stream maps (VSM). We deep dive into a VSM to understand the four elements (material and information flow, timeline and data boxes), different states of a VSM (current, ideal and future), and review common VSM symbols and metrics used in a VSM. We provide a roadmap on how to create a VSM, along with some examples and best practices.
- Process Measures and Data Display – Theory & Quiz
In this section, we will discuss different types of data, along with commonly used metrics to measure the efficiency and performance of your processes, such as yield, process cycle time, takt time, queue time, changeover time, work time vs calendar time, lead time, and the theory behind Little’s Law. We will also discuss some simple ways to represent and summarize your data using charts and graphs such as a bar chart, time series plots and Pareto charts.
- Root Cause Analysis – Theory & Quiz
Before we come up with countermeasures and potential solutions to our problems, we first need to make sure we are addressing the root cause of the problem, not the symptoms of the problem. We will provide some definitions of a root cause and a point of cause, and why we need to get beyond fire fighting in our organization. We will cover 3 commonly used tools that can help you get to the root cause: 5 Why’s, Cause Tree and the Fishbone (Cause and Effect) Diagram.
- Lean Principle – Create Flow – Theory & Quiz
Establishing consistent flow of work in a process is critical to operational excellence. Once we start working on an order or customer request, the goal is to never stop working on it until it is complete. Everytime it stops or gets put aside, we have disrupted the flow. This section covers techniques to improve the flow in a system using techniques such as a Spaghetti Diagram, calculating takt time and pitch, workload balancing, escalating problems using andon and other triggers, and reducing setup time with rapid changeover methods.
- Lean Principle – Establish Pull – Theory & Quiz
Once you have established good flow in your process, we can transition away from a push system to a pull system, where work is done only when a trigger is given from the next step. We will explain the differences between a push and pull system, why a pull system is better, and different types of methods for implementing pull. Methods include WIP Capacity, Kanban, 2-Bin Replenishment systems and other signaling devices. We share a few video examples of different types of kanban systems, and review an equation for calculating the correct kanban sizes.
- Mistake Proofing – Theory & Quiz
Telling employees to be more careful or adding inspection after every step of the process is not an effective approach for reducing errors. Humans are going to make mistakes, so we need to plan for these mistakes, and come up with cost-effective devices that prevent the error or detect it right away (called Poka-Yoke devices). We will explain the cost of allowing errors to escape through your processes, and how to approach human errors in a positive way. You will learn about Shigeo Shingo and W. Edwards Deming and how they focused on reducing human errors. You will learn to identify “red flag” areas that are most prone to errors, and 6 mistake proofing principles you can consider when creating your own device.
- Pursue Perfection – Theory & Quiz
The fifth principle of Lean is pursuing perfection, which drives the need to continuously improve. In this section, we will discuss how standardized work is a core foundation for improvement to hold the gains. We will discuss steps to create standard work, and show the benefits of standard work using the “Draw a Pig” exercise.
- Ideal and Future States – Theory & Quiz
In this section, we will review Toyota’s True North concept, along with the Ideal State of a process (without waste and quick response). We will spend most of the module on the Future State of a process by discussing how to ask good questions using the 5 W’s, conduct a brainstorming session, and common strategies for improvement called ECRS (Eliminate, Combine, Rearrange and Simplify).
- Lean Six Sigma – Theory & Quiz
Now that you’ve learned about Lean, we want to introduce you to another popular improvement method called Six Sigma. We will introduce the process thinking approach of managing input variables instead of reacting to the output variables, and how Six Sigma focuses more intently on data collection and analysis. We’ll review the history of Lean and Six Sigma, how Lean and Six Sigma tackle improvements differently, how the number of process steps and process yield impact operational excellence, and how best to blend Lean and Six Sigma together to utilize the strengths of each method.
- Wrap Up – Theory & Quiz
In this section, we will recap all the previous modules to tie all the concepts together.
What’s included in the Online Training
- Lean Introduction Training
- Closed captioning transcript provided with all videos
- Each module requires completion of a quiz (retakes allowed).
- Digital version of the complete Lean Fundamentals program (read-only)
- On-demand, 24/7 access with 6 months of access to professionally narrated OpEx Learning training course
- Online Quizzes and Exam, including final comprehensive examination.
- Upon completion of the training and passing the examinations, you will receive:
- Lean Fundamentals Training Certificate
Popular Job Roles/Positions
- Lean Engineer
- Lean Specialist
- Lean Leader/Expert
- Lean Agent/Consultant/Advisor
- Lean Project Manager
Few Hiring Companies
- GE Aviation
- Thermo Fisher
How it Works
Online Training & Examination
Six Sigma Certification
Why Choose OpEx Learning
We know there’s a bunch of other Lean Six Sigma providers out there, but here’s why you should choose us:
- We are authorized by the ISSSP, IACET and are a PMI approved educational provider. This means your qualification meets the highest global standards.
- The positive real-world results of OpEx Learning courses have been proven innumerably.
- Our instructors are leading & highly experienced Lean Six Sigma Master Black Belt holders: The best of the best.
What people say about OpEx Learning?
I thoroughly enjoyed the White Belt training and the website was easy to navigate. I would definitely recommend it to anyone interested in Lean Six Sigma. Thank you OpEx Learning.
The program is well designed in touches on all the basics of 6-Sigma. This is an easy to follow course that, I believe, would help companies if presented to employees in the operational level.
Kendry Bautista M.
The Lean Six Sigma White Belt course was very accessible for me as a school administrator. I will definitely use the resources for project management and strategic planning.
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- On demand, 24/7 access to the training program with the ease to access from your home or office
- Self-paced program to help you cover the topics at your own speed
- Covers everything from the complete Lean Intro classroom program
- World-class programs emphasizing a practical approach geared to delivering real-world results and crafted by the best instructors across the globe
- Includes case studies and real-world Lean implementation examples.
Lean — Engaging employees to increase customer value
Lean focuses on process efficiency and reducing or eliminating waste in processes by using various methods to streamline processes and strive for continuous improvement. The fundamental basis for the success of Lean is the ability to identify and eliminate waste, aggressively reduce non-value-added activities, and improve flow in any organization’s processes.