Lean Fundamentals

Programme Objectives

The key objectives of the training are to:

• Build a shared understanding of lean principles across the team
• Introduce practical methods to identify and reduce waste
• Provide tools to improve process flow, standardisation, and visual management
• Strengthen the team’s problem-solving and continuous improvement capability
• Support leaders in sustaining change within day-to-day operations
  
  

Training Structure

Introduction to Lean Principles and Manufacturing Terminology

Introduction to the origins and purpose of lean manufacturing, including key principles such
as value, flow, pull, and continuous improvement.

Common lean terms are explained using manufacturing-specific language and examples to ensure a consistent understanding across the team.

Understanding Value-Adding vs Non-Value-Adding Activity

Exploration of what constitutes value from a customer and manufacturing perspective.

Participants learn how to distinguish between value-adding, non-value-adding, and
necessary but non-value-adding activities within machining, fabrication, assembly,
inspection, and material handling processes.

The 8 Wastes in a Manufacturing Environment

Detailed review of the 8 wastes (Defects, Overproduction, Waiting, Non-utilised Talent,
Transportation, Inventory, Motion, and Over-processing), with practical examples of how
these wastes typically appear on the shop floor, in production planning, and across material
and information flow at Serrations.

Training Structure

Process Flow, Standardisation, and Visual Management

Introduction to the principles of process flow and why poor flow drives inefficiency, delays,
and excess work-in-progress.

Overview of standardised work and visual management techniques commonly used in manufacturing to improve consistency, highlight problems quickly, and support safer, more controlled operations.

Applied Lean Exercises Using Real Manufacturing Examples

Practical exercises based on real processes, products, or scenarios from within the business.
Participants work through examples to identify waste, map simple process flows, and
consider practical improvements that can be applied directly back in the workplace.

Current Manufacturing Challenges and Improvement Opportunities

Facilitated discussion focused on current operational challenges such as bottlenecks,
rework, planning issues, material flow, or communication gaps. The session encourages
shared learning and begins to identify priority improvement opportunities aligned to lean
principles.

Training Structure

Outcome

A shared, practical understanding of lean manufacturing principles, with a common
language for identifying waste, improving flow, and supporting more efficient, consistent
day-to-day operations on the shop floor.

Programme Structure

Day 2 – Applying Lean in Practice

Applying Lean Tools

Recap of key lean principles from Day 1, followed by a practical focus on applying lean
thinking to real environments. Participants explore how lean tools support better control of
quality, delivery, safety, and cost in day-to-day operations.

Identifying Waste, Bottlenecks, and Flow Constraints

Practical identification of waste and inefficiencies within material, product, and information flow.

Participants will learn how to recognise common constraints such as batching, poor
layout, unbalanced workloads, excessive handling, and unclear priorities that restrict flow
and drive delays.

Programme Structure

Hands-On Lean Simulation: Plug Assembly Line

A practical, interactive assembly simulation used to demonstrate lean principles in action.
Participants complete an initial assembly round to establish baseline performance,
highlighting issues such as overproduction, waiting, defects, poor layout, and lack of
standard work.

Lean concepts are then introduced and applied, including improved flow, simple
standardisation, visual controls, and workload balance followed by repeat assembly rounds
to clearly demonstrate measurable improvements in productivity, quality, and flow.
The exercise makes improvement visible and reinforces how small, practical changes can
deliver significant operational benefits.

Programme Structure

Introduction to Practical Problem-Solving Techniques

Introduction to simple, structured problem-solving approaches suitable for manufacturing
environments.

Participants learn how to define problems clearly, identify root causes, and agree practical countermeasures that can be implemented quickly on the shop floor.

Visual Management and Standard Work in Practice

Hands-on exploration of visual management and standardised work, focusing on how these
tools support consistency, faster decision-making, and early problem identification.

Discussion centres on practical examples relevant to Serrations’ operations rather than
theoretical models.

Leadership Discussion – Embedding and Sustaining Lean Improvements

Facilitated discussion with supervisors and team leaders on how lean behaviours are
sustained beyond initial improvements.

Focus on daily routines, team communication, visual controls, and leadership behaviours that reinforce continuous improvement as part of normal operations.

Training Structure

Outcome

Team members leave with practical, immediately applicable lean skills and a clear
understanding of how improving flow, reducing waste, and applying standard ways of
working can positively impact safety, quality, delivery, and efficiency across day-to-day
manufacturing operations.

 

Benefits

 

This 2-day, in person Lean Fundamentals training provides participants with the practical
skills and understanding needed to reduce waste, improve flow, and embed consistent ways
of working. By applying lean principles to real shop floor processes, learners will develop
the capability to drive immediate operational improvements, strengthen day-to-day control,
and build a solid foundation for sustained performance and future improvement activity.

Learner will gain:

– A clear, practical understanding of lean manufacturing principles applicable across a wide
range of production environments

– The ability to identify and reduce waste while improving flow across core manufacturing
activities

– Practical tools for standardisation and visual management that support consistent
working and rapid problem identification

– Increased confidence in identifying bottlenecks, constraints, and improvement
opportunities on the shop floor

– Hands-on experience of lean in action, demonstrating how small, structured changes can
deliver measurable operational improvements