Lean Manufacturing

Introduction

Indian factories compete on cost and flexibility, yet waste continues to swallow 20–30 % of value. Lean Manufacturing training equips teams to identify and eliminate the seven classic wastes—transport, inventory, motion, waiting, over-production, over-processing, and defects—releasing capacity without capital spend.

Program Goals

Three-Day Intensive Format

Day	Focus	On-Floor Exercise
1	Lean Principles & 5S	Red-tag campaign in one zone
2	Value-Stream Mapping & Kaizen	Map current vs future state of a pilot product
3	Pull Systems & Standard Work	Design Kanban loop, create standard work sheet

Essential Toolkits (Take-Home)

Benefits & Target KPIs

KPI	Baseline	90-Day Target
Floor space utilization	70 %	85 %
WIP days of cover	22	≤ 12
First-pass yield	89 %	≥ 96 %
5S audit score	55/100	≥ 80/100

Success Story

A Gujarat textile mill implemented 5S and single-piece flow on its winding line, reducing changeover time by 43 % and freeing 1 000 sq ft of space which they repurposed for a sampling cell generating ₹1.2 crore additional revenue annually.

FAQs

How many employees can join?

One core team of 15–20 runs the pilot; knowledge then cascades through train-the-trainer.

Will output drop during the course?

A short dip on Day 1 is common; by Day 3 pilot cells usually exceed previous output.

Do you supply labels and boards?

Starter kits with red tags, floor tape, and shadow boards are included.

Is lean only for high-volume lines?

No—job shops and process industries benefit equally through layout and batch-size optimisation.