APICS – Lean Enterprise Workshop Series

Lean Manufacturing - IIBLC® - Courses and Master's


4 days




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Courses and Master's

APICS – Lean Enterprise Workshop Series

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The Lean Enterprise Workshop Series, developed by APICS, addresses all issues for the successful implementation of a Lean project. The worsening trend in the KPIs of the company in the programme case study prompts its managers to initiate a Lean process via a structured roadmap that determines the entire course.

The course describes the profound changes the company will have to undergo to improve its KPIs by adopting the Lean philosophy.

The programme illustrates all the Lean concepts, such as Jit, Heijunka, Takt Time, Value Stream adopted in the Toyota Production System, and harmonises these with the APICS body of knowledge: this new key reading – referencing a structured change roadmap and a case study analysis of a Lean transformation – are the new elements of this innovative course.

The course is only available In-house.


  • to transfer the Lean vision of how to create Value for the Customer
  • to provide specific Lean skills, as well as techniques and tools to identify the flow of Value and identify sources of waste
  • to provide a structured approach for successful Lean implementation that describes the necessary cultural and organisational changes
  • to accelerate learning by showing the critical issues to be tackled and the solutions adopted via a Lean implementation business case study.
  • Teaching plan

    The study plan comprises the course structure and the programme specification. The  course is structured across 4 training days. Below is the main content.


    • Current Situation at Murphy’s Toys
    • Murphy’s Toys Learns About Lean
    • House of Toyota
    • Lean Principles: Value, Value Stream and waste elimination
    • Value added activities
    • Correcting The Eight Deadly Wastes
    • Muda, Mura and Muri
    • Murphy’s Toys Plans a Lean Transformation
    • Lean Readiness Assessment
    • Define Product Families
    • A Vision for Lean
    • The core of Lean: Respect for People, Change Management and Kaizen
    • Employee Involvement in Lean
    • Change Management
    • Lean Culture
    • Lean Teams
    • Form and Train Kaizen teams
    • Jidoka and autonomation
    • Mistake-proofing and Poka –Yoke
    • Pilot Lean implementation
    • Murphy’s Toys Pilot Product Family
    3. MAPPING
    • The Lean Roadmap
    • Value Stream Map
    • Product/Process Matrix
    • Takt Time and Pitch Time
    • Performance Process Data
    • Describing current state in Murphy’s Toys
    • Timeline
    • Interval
    • Finished Good strategy: how to buffer from variability of demand
    • The Hierarchy of flow: Continuous, FIFO and PULL
    • Heijunka
    • Achieving Demand Stability
    • Value Stream Loops
    • Load Leveling
    • Mixed-Model Production
    • Buffering
    • Achieving Process Stability
    • Causes of Process Variability
    • Process Improvement
    • Standard Work
    • Plan for Every Part (PFEP)
    • Total Productive Maintenance (TPM)
    • Six Sigma
    • SMED
    • 5S
    • Customer Demand and Takt time
    • Type of flows
    • Production cell varieties
    • The Line Balance Chart
    • One piece flow vs Batch flow
    • The Supermarket Pull System
    • Kanban
    • Two ways of level scheduling: Pace withdrawal and Heijunka
    • Mixed Model Scheduling
    • MRPII
    • The Pacemaker
    • Traditional vs Lean measurements
    • Traditional vs Lean Thinking
    • Lead Time elements and calculation
    • Traditional vs Lean accounting
    • Value Stream Costing
    • Lean measurements: FTT, Units per Person, Inventory Days, On-Time delivery,
    • OEE, Value Stream P&L, Lead Times, Defect Per Million parts
    • Alignment Chart
    • Target Costing
    • DFMA (Design for Manufacture and Assembly)
    • Traditional vs Concurrent Design Lead Time
    • Reducing the Bill of Material
    • House of Quality and QFD
    • FMEA (Failure Mode and Effects Analysis)
    • Plan-Do-Check-Action (PDCA)
    • Six Sigma
    • DMAIC (5 Six Sigma steps)
    • The Seven Tools of Quality
    • Sustaining Success
  • Who is the course aimed at

    The course targets the following professional figures:


    • Plant Managers
    • Representatives and staff in the areas of Production, Supply Chain, Quality, Purchasing and Organisation in the Industrial and Services sectors;
    • Future Lean transformation team Leaders with Black Belt competence
    • Companies wishing to implement Lean, and to train Project Leaders via a structured and up-to-date course
    • Operations Consultants
    • Production and Process Engineers