Course Category: Lean

Course Format: Face-to-face, Online, Virtual

Course Solution: Process

As teachers, mentors, project leaders and change agents, Lean Masters play a critical role in driving quantifiable improvements throughout their organizations. This program prepares future Lean Masters in a challenging and rigorous manner so they can perform effectively in their new roles.

The differentiating aspects of this program are its discipline, its personalized attention provided to each candidate by a designated Lean Methods Group Lean Master, its flexibility in learning modes (virtual live classroom with online support) and its self-paced schedule.

Lean Master candidates begin their course of study and application by getting paired with a Lean Methods’ Lean Master who coaches you through every step of the certification process—helping you complete your coursework, pass the exams, run your Kaizen events and complete the report.

Course Category:

Course Format:
Face-to-face, Online, Virtual

Course Solution:

Course Price:

Course Modules

The Eight Types of Waste

   Module Duration: 43 min

This course teaches how to identify eight types of waste (non-value-added activities) and how to define value from the customer’s perspective.


   Module Duration: 70 min

This course teaches the 5S method of eliminating waste: Sort, Store, Shine, Standardize, and Sustain.

High-Level Process Maps

   Module Duration: 24 min

In this module, students are introduced to high-level process maps, specifically Macro Maps and SIPOC Diagrams. Coverage includes the purpose of each map, the steps necessary to create each map, and a demonstration of how to apply each map.

Mid-Level Process Maps

   Module Duration: 31 min

Mid-level process maps provide a clear and in-depth understanding of a process in order to improve it. In this module, students learn how to create a Process Flow Diagram that leverages Value Add/Non-Value Add analysis, and also how to create a Swimlane Map that correlates process steps with accountability.

Process Analysis Tools

   Module Duration: 31 min

This module focuses on two tools that can be used to analyze a specific step in a process: Detailed Process Maps and Standard Work Combination Sheets. Students will learn the purpose of each tool and when they should be used, as well as how to construct each tool.

Spaghetti Diagrams

   Module Duration: 17 min

This module explains how to create a Spaghetti Diagram, as well as how to analyze the results to reduce wasted movement.

Fishbone Diagrams

   Module Duration: 14 min

This module introduces the Fishbone Diagram, its purpose, and its application. It also explains how to construct a Fishbone Diagram.

Creating Pareto Charts

   Module Duration: 17 min

This module introduces the Pareto Principle, which suggests that a large majority of problems (80%) are produced by a few key causes (20%). It also demonstrates how to construct and analyze a Pareto Chart.

Current State Value Stream Maps

   Module Duration: 41 min

This course explains a primary Lean concept, value stream mapping, and its role in identifying waste in and between processes. The course reviews an 8-step process for creating a value stream map and discusses the analysis techniques used to interpret the data.

Future State Value Stream Maps

   Module Duration: 29 min

This module explains the concept of a “future state” value stream map. It discusses how to design the future, or ideal, state of a process take time. It also describes methods to achieve the future state, including spaghetti diagrams, cellular layout, 5S, and visual controls.


   Module Duration: 39 min

This module introduces the concept of Flow, which is the balancing of internal resources to meet external demand. Topics include Takt Time, Cycle Time, Lead Time, Work Flow Balance, Standard Work and Cellular Design.

Standard Work

   Module Duration: 36 min

This module addresses three different components of standard work: ‘takt’ time or customer demand; Work in Process (WIP), which is the minimum amount of inventory needed in order to achieve a smooth flow; and Standard Operating Procedures (SOPs) to document standard routines or procedures.

Visual Management

   Module Duration: 33 min

This module discusses how visual management techniques can be used to enable process control. It provides examples of visual signals used across a variety of industries, as well as discusses a plan that can be used to implement visual management within a company.


   Module Duration: 32 min

This module defines the Lean concept of Pull, and how to build a Pull system to regulate the flow of production. As part of the discussion, it covers how to calculate lead time and work-in-process, Little’s Law, and Kanban.


   Module Duration: 27 min

This course discusses the concept of “Kanban” which simply means “visual signal.” It introduces how to use Kanban to control the movement and production of new inventory.

Preventing Human Error

   Module Duration: 50 min

This course explains how human factors result in errors. It presents the work of two behavioral scientists, which describes how humans behave in three different modes and the methods that can be used in each to prevent human error.

Reducing Setup Time

   Module Duration: 31 min

Reducing the time it takes to move from one process to another is critical to improving productivity, quality and customer satisfaction. In this module, students will learn the best method to document long setups, as well as the 5-step process for reducing setup time.