Lean Manufacturing. Lean Production. Kaizen

The seminar shows how to build an efficient production management system and improve existing processes. Participants will examine the principles of lean manufacturing and gain practical tools that industrial companies use to reduce waste, improve quality, and shorten order lead times.

The seminar is based on the Toyota Production System, known as Lean Production. Its core idea is to align production with customer needs by systematically eliminating waste. The transition to lean manufacturing often does not require major investment: there is no need to buy new equipment right away, change materials, or implement an expensive ERP system. What matters most is changing the management culture, the interaction between levels and departments, and employees' attitude toward their work.

Seminar program

1. The lean manufacturing concept

• Cost reduction as the core principle of organizing production.
• Origins, the Toyota Production System, key principles and elements.
• Waste as hidden costs.

2. Core elements of the system

• 5S (seiri, seiton, seiso, seiketsu, shitsuke) — workplace organization and process visualization to identify waste.
• Visual management — quick access to information for timely decisions.
• Standardization — the foundation of process stability and quality.
• A continuous improvement system — engaging employees in cost reduction.
• Just-in-time: flow, kanban, heijunka — faster order fulfillment and lower inventory.
• Andon, work teams, safety management (risk assessment, ergonomics, environment), change management, quality, key performance indicators.

3. Efficiency improvement tools

• Gemba and kaizen.
• The 8 types of waste and methods for finding them.
• SMED — quick equipment changeover.
• TPM (Total Productive Maintenance).
• Poka-yoke — error-proofing.
• Yamazumi — line balancing and productivity growth.
• Spaghetti diagram — identifying unnecessary movement.
• Problem solving and root cause analysis.

4. Value stream mapping (VSM)

• Building a current-state map.
• Analyzing value-adding and non-value-adding operations.
• Finding bottlenecks and tools for eliminating waste.
• The future-state map and a change roadmap.

5. IATF 16949 tools (formerly ISO/TS 16949)

• The control plan as a quality control tool.
• FMEA — failure mode and effects analysis for risk assessment and cost reduction.

6. Implementation at your company

• Results of applying lean manufacturing.
• Common implementation challenges and how to overcome them.
• Experience of companies that have implemented Lean.

Who the seminar is for

For company and plant managers, technical specialists, and anyone responsible for managing the production process.

How the sessions work

Sessions are highly interactive between the trainer and participants: small-group work, brainstorming, visual materials, and simulations of work situations. Participants analyze their own experience, compare it with new knowledge, and draw conclusions with the facilitator's help. The seminar ends with answers to questions and practical recommendations.

In the corporate format, a lean manufacturing business game is held: participants build several production models, apply Lean tools, and calculate the benefits of using them.

Before the seminar, we recommend sending in your most pressing questions on the topic so that the discussion is closer to your company's challenges. The seminar can be held in a corporate or individual format, as well as online. Learn more about corporate training in the Programs section; upcoming dates are in the Schedule section.

Materials and certificate

Participants receive handouts. At the end of the seminar, an HSE IPAA certificate of completion is issued.

Instructors

The seminar is led by lecturers with practical experience in the subject. The facilitator is confirmed closer to the date and can be provided on request.