Lean Six Sigma & Operational Excellence
Lean Product Development & Lean Project Management Tools
Apply Lean upstream to product development. The course covers waste in development, value stream mapping of the development process, integrated teams, the 3P approach, visual project boards and stand-up meetings, helping teams shorten time to market and improve manufacturability.
At a glance
Catalog codeA23
Duration
- 2 days
LevelPractitioner
Program typeWorkshop
LanguageEnglish / Arabic
DeliveryIn-house · Public · Online
Who it's for
- Product development engineers, project managers and R&D leaders
Learning objectives
- Reduce time to market with lean product development
- Eliminate waste in development
- Use integrated teams, visual boards and stand- ups
Detailed content
- What makes product development different from production
- Value, waste and knowledge flow in engineering
- Value-added, waste and enabling work
- Set-based concurrent engineering and front-loading
- VSM for product development: calendar time, work time, value-added time
- Identifying queues, rework loops and hand-offs
- Designing the future-state development flow
- Production preparation process (3P)
- Chief-engineer system and integrated project teams
- Design for manufacture and assembly (DFM/A)
- Knowledge reuse: checklists, trade-off curves, A3 reports
- Planning only value-added work
- Pull planning and the Last Planner approach
- Visual project boards and daily stand-up meetings
- Exception management and fast escalation
- Lean metrics for project flow
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- Lean product development principles
- Mapping the development value stream
- Toyota methods
- Lean project management
- 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
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 Product Development & Lean Project Management Tools?
The program runs 2 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.