Lean Manager

By the end of this course, participants will be able to:

• Understand the role and responsibilities of a Lean Leader and apply key leadership routines.
• Implement a Performance Management System to monitor, analyze, and drive operational results.
• Apply standardization, process confirmation, and visual management for sustainable improvement.
• Manage skills, capacity, and workload to balance performance and flexibility.
• Foster team engagement through Kaizen and Jidoka principles.
• Lead organizational transformation through Hoshin Kanri and OKR deployment.
• Create a Lean culture where everyone contributes to daily improvement.

1. The Role of a Lean Leader

• Missions and responsibilities of a Lean Manager
  • Gemba Kanri principles
  • Lean Leader vs. Team Leader / Deputy / Lean Sensei
• Leader Standard Work (LSW)
  • Daily, weekly, and monthly routines
  • Building a standard agenda
• Management for Daily Improvement (MDI)
  • Daily team meetings, information centers, MBWA, structured problem-solving
• Gemba Walks
  • Preparation, objectives, tools, and post-Gemba follow-up

2. Performance Management

• Performance Management System
  • The 4 steps of a performance management cycle
  • Practical implementation and operational dashboards
  • KPI design, visualization, analysis, and interpretation
  • AIC (Active Information Centers) and communication routines
  • Individual performance management
  • OEE (Overall Equipment Effectiveness) and its adaptation to knowledge work
• Standardization (SOP & Visual Management)
  • Roles and responsibilities in standardization
  • SOP elements (Takt Time, Sequence, WIP)
  • Best practices and pitfalls in SOP design
  • One-Point Lessons and the PCF model
  • Process Confirmation techniques
• Short-Term Action Management
  • Using the A3 tool to track and solve issues

3. Capacity & Competency Management

• Skills Management
  • Skill Matrix structure and competency levels
  • Gap, risk, and distribution analyses
  • Competency development plans
• Capacity Management
  • Annual capacity planning
  • Sequential flow scheduling (OFS)
  • Task distribution and tracking tools:
    • Heijunka Box
    • Kamishibai Board
    • Kanban Board

4. Team Engagement through Kaizen

• Jidoka (Stop & Fix)
  • The 4 steps of Jidoka and its intellectual application
  • Andon systems for visibility and response
• Embedding Lean Culture
  • Difference between culture and work environment
  • The 10 workplace factors impacting improvement potential (Ekvall)
• Managing Change Dynamics
  • The two root causes of resistance to Lean
  • Profiles of change (advocates, agnostics, antibodies)
  • Kübler-Ross curve and the 7 resistance types
  • Targeted strategies to overcome resistance
• Kobetsu Kaizen
  • The 8 steps of Kobetsu Kaizen
  • Using Kaizen to empower individuals and teams

5. Strategy Deployment and Vision Cascade

Understanding Mission, Vision, Strategy, and Action Plans

• Hoshin Kanri (Policy Deployment – Toyota)
  • Key differences with Management by Objectives
  • The 7 steps of Hoshin Planning: from vision to review
  • Tools: X-Matrix, Bowling Chart, Sunray Diagram
• OKR Method (Objectives & Key Results – Intel)
  • Differences vs. Hoshin Kanri
  • Defining Objectives, Key Results, and Initiatives
  • The 8 criteria for effective objective-setting
  • OKR scoring, confidence levels, and cadence
  • Integrating OKRs into existing meetings
• Action Plan Governance
  • The 3 early warning signals in strategy deployment

This program is ideal for:

• Managers, supervisors, and Lean leaders driving operational excellence
• Continuous improvement professionals (Lean, Six Sigma, or OpEx backgrounds)
• Project managers, team leaders, and process owners seeking structured improvement systems
• Anyone aiming to develop leadership capabilities and embed a Lean culture within their organization
• Applicable across all sectors: manufacturing, services, logistics, healthcare, IT, and public administration.

Our methodology ensures practical learning and real-world results:

• Interactive workshops based on participants’ actual challenges
• Simulations and case studies to practice Lean leadership and MDI routines
• Hands-on exercises on performance dashboards, SOPs, and skill matrices
• Gemba-based learning, encouraging field observation and direct problem-solving
• Coaching and peer feedback from certified Lean experts
• Access to digital tools, templates, and best practices for immediate implementation