Training Lean Thinking In Improving Workplaces


Lean Thinking is a focus on eliminating waste so that all processes in the total system, process, servicing or production line add value from the Customer Perspective. Lean Thinking is not about:

(1). Staff Cuts;

(2). Assigning Blame, and;

(3). Nominal or One-Time Changes.

There are five principles of lean thinking: Value, Value Stream, Flow, Pull and Perfection.

VALUE is defined as a “capability provided to customer at the right time at an appropriate price, as defined in each case by the customer. Value is the critical starting point for lean thinking and can only be defined by the ultimate end customer.

The VALUE STREAM is defined as the set of all the “specific activities required to design, order, and provide a specific product, from concept to launch, order to delivery, and raw materials into the hands of the customer. To create a value stream, describe what happens to a product at each step in its production, from design to order to raw material to delivery. There are three types of activities in the value stream – one kind adds value, and the other two are “muda” (the Japanese word for waste):

Value-Added: Those activities that unambiguously create value.

Type One Muda: Activities that create no value but seem to be unavoidable with current technologies or production assets.

Type Two Muda: Activities that create no value and are immediately avoidable.

Some examples of muda are mistakes which require rectification, groups of people in a downstream

activity waiting on an upstream activity, or goods which don’t meet the needs of the customer.

The lean principle of FLOW is defined as the progressive achievement of tasks along the value stream so that a product proceeds from design to launch, order to delivery and raw materials into the hands of the customer with no stoppages, scrap or backflows.

The fourth lean principle of PULL is defined as a “system of cascading production and delivery instructions from downstream to upstream in which nothing is produced by the upstream supplier until the downstream customer signals a need.

The fifth and final lean principle is PERFECTION, defined as the “complete elimination of muda so that all activities along a value stream create value. This fifth principle makes the pursuit of lean a never-ending process, as there will always be activities that are considered muda in the value stream and the complete elimination of muda is more of a desired end-state that a truly achievable goal.



  1. Basics of LEAN
  2. Definition of WASTE
  3. Consequences of WASTE.
  4. Value-Added & Non-Value Added.
  5. Identification of Mr. TIMWOODS
  6. Steps in LEAN PROCESS
  7. LEAN Tools
  8. Value Stream Mapping
  9. Key Factors of Successful Lean Implementation

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