Lean Six Sigma & Operational Excellence
Lean Manufacturing
A practical Lean Manufacturing programme that moves participants from push to pull production. Content scales with duration – from Lean foundations, flow metrics and VSM, to cells, SMED, kanban, levelling, TPM and sustainment – with simulations, videos and implementation projects in the longer formats.
At a glance
Catalog codeA19
Duration
- 1–2 days · Live simulation
- 3 days · Awareness
- 5 days · Practitioner / Lean Green Belt
- 8 days · Level 1 with implementation
- 12 days · Comprehensive
LevelPractitioner
Program typeProfessional Course
LanguageEnglish / Arabic
DeliveryIn-house · Public · Online
Who it's for
- Production, maintenance & planning teams
- Process management & quality control teams
- Quality managers & process supervisors
Learning objectives
- Understand Lean philosophy, TPS and the 8 wastes
- Measure flow: cycle time, takt, lead time, PCE, OEE, standard time
- Map current and future value streams
- Create flow and pull: cells, SMED, levelling, kanban
- Use 5S, visual management, TPM, poka-yoke and A3
- Run Kaizen/Kaikaku projects and sustain results (Kata)
Detailed content
- Operational excellence approaches (Six Sigma, BPR, TQM, TOC, Kaizen)
- Value to customer; what is Lean
- Push vs pull; TPS, JIT & Kaizen
- Lean principles; Lean enterprise & design
- Simulation 1
- Lean benefits; JIT pull
- Manufacturing methods
- Cycle time, lead time & PCE
- Takt time calculations
- Value-added vs non-value-added; 8 wastes
- Gemba walk
- Standard time & SOP; OEE
- Current-state VSM
- Simulation 2
- 5S+Safety & visual management/control
- 5 Whys & fishbone
- Cell design
- Assembly line balancing (8-day)
- TPM & OEE
- Quick changeover / SMED
- Poka-yoke
- Production levelling
- Kanban material management
- Inventory management & queuing
- Kaizen & Kaikaku projects; A3
- Productivity calculations
- Future-state map
- Sustaining the improvement
- Implementation on site (8-day)
- Toyota Kata
- Energy efficiency
- Cleaner production
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- Lean Foundations (all formats)
- Measuring the Process (all formats)
- Value Stream Mapping (all formats)
- Flow & Workplace (5+ days)
- Pull (5+ days)
- Improvement & Sustainment (8+ days)
- Advanced (12 days)
- Case study, action plans and course assessment
Practice, tools and assessment
Hands-on practice
- Walk the process and draw a current-state value stream map with real times
- Calculate lead time, process cycle efficiency and takt time
- Design the future-state map and a 90-day implementation plan
- Waste walk (gemba) using the 8-waste checklist
Tools and templates you keep
- VSM icon set and data-box template
- Takt/lead-time calculator (Excel)
- 8-waste observation sheet
- Kaizen event charter and newspaper (action list)
How learning is assessed
- Pre- and post-course knowledge check
- Assessment of practical exercises by the trainer
- Action plan reviewed at the end of the course
Built on these standards and bodies of knowledge
- Rother & Shook, Learning to See (Lean Enterprise Institute)
- Lean Enterprise Institute principles (Womack & Jones)
- Toyota Production System
How it is delivered
- Public courses in Cairo, in-company programs and live online training
- Practical exercises, case studies and examples from your sector
- Can also run as Train & Stay in Sharm El Sheikh, Hurghada or Cairo
Part of these career paths
- Operational Excellence & Lean Six Sigma · Practitioner
What participants say
“When I started the course I was a quality specialist; after it I was promoted to quality team leader. Six Sigma changed a lot for me. Very comprehensive – I'd suggest it 100%.”
“The course teaches you to take hold of a problem logically and solve it scientifically. The explanation was simple, and this way of thinking matters for life as a whole.”
“What I gained most: I never imagined how much money projects can lose. We ran a small cost project on our site and found mistakes we can now avoid.”
FAQ
Frequently asked questions
How long is Lean Manufacturing?
The program runs 1–2 days; other formats: 3 days, 5 days, 8 days, 12 days. In-company versions can be adapted to your needs.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
Will I receive a certificate?
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
More programs in this field
- Applied Statistics for Six Sigma3 days
- Foundations of Operational Excellence3 days
- Lean Six Sigma Black Belt20–25 days
- Lean Six Sigma Champion (Sector Managers & Directors)2 days
- Lean Six Sigma Green Belt9–10 days
- Lean Six Sigma Master Black Belt10 days
- Lean Six Sigma Orange Belt5 days
- Lean Six Sigma White Belt (Awareness)1 day
- Lean Six Sigma with Value Stream Mapping (5-day practitioner / 12-day Green Belt track)5 days
Get dates, fees and the full outline.
Tell us whether you are joining as an individual or planning a program for your team.