Lean Process Improvement

Lean process improvement is a system of steps that help organisations reduce waste by focusing on customer value. By identifying how customer value flows across every aspect of the organisation, management & teams can then fine-tune and implement processes that create zero waste.

The PD Training Lean Process Improvement Training course will enable teams with the right tools to implement lean principles of process improvement into the very core of their culture, thereby reducing waste and improving product and service value to the customer. Tools covered include 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu.

Lean Training courses delivered Australia-wide by LSS experts in Brisbane, Sydney,, Melbourne, Canberra, Adelaide and Perth. Ph: 1300 121 400

Your Learning Outcomes

After Completing this Course Participants Will:

  • Gain an understanding of Lean
  • Describe "The Toyota Production System" and TPS house.
  • Master the five Lean principles
  • Learn how to categorise products or systems into the three groups
  • Learn how to create and contribute to a Lean enterprise
  • Identify and reduce various types of organisational waste
  • Learn to create a plan for an organisation that's more environmentally Lean
  • Learn how to implement & evaluate Lean changes with PDSA cycle R-DMAIC-S models
  • Learn how to effectively use Lean thinking frameworks like 5W-2H, Genchi Genbutsu, Gemba, and 5-S
  • Prepare for and complete a basic 5-S
  • Learn the five levels of Kaizen events, particularly a Kaizen blitz
  • Effective tips for data gathering, mapping and analysis using flow charts, Ishikawa and SIPOC diagrams, and value stream maps
  • Create a successful plan for a Lean project
Duration: 2.0 day course Live Online Experts


Lean Process Improvement Reviews:

"Training was well conducted and I have gained a lot from it....Andrew was very helpful, flexible and accommodating with anything related to the course. Looking forward to do more courses with you next time."

IAG Insurance Australia Group


"It was great that he was able to come in to our office to offer a one-on-one training session. There was a lot of information to take in, but it was definitely helpful for me and my role."



"Peter was very flexible in his approach and covered a lot of content over the 2 days. It was an excellent training workshop."

-Hume City Council


"As expected, the course was manufacturing oriented. However, it reinforced I was on the right track with current projects and re-introduced tools from other courses I had attended but not considered applying to my current role."

-Deakin University


"This was a good course to change the mindset to lean way of thinking in the workplace. The tools provided were a great base for starting knowledge in lean."

-Royal Australian Mint


"Great course, the content was structured really well for us to get maximum benefit from it."

-Callida Consulting


"Great course and well delivered by the trainer."



"This course proved to be surprisingly practical, thanks to the inclusion of the many workshops and the interaction encouraged by the presenter. I came away with many useful tools to apply the principles of LEAN and with many constructive ideas and concepts, specifically tailored to the work which we do at Douglas Partners."

-Douglas Partners

More happy clients 

Download Course Outline (PDF)

This two-day Lean Process Improvement training course will give your organisation the foundational tools required to implement Lean thinking and solutions.


Day one explores the foundational Toyota precepts of Lean and the five improvement concepts: value, waste, variation, complexity and continuous improvement.


The second day will focus on how to use the actual tools for implementing these continual improvement concepts in an organisation. Useful tools will include; Lean data mapping methods, 5S, 5W-2H, PDSA, DMAIC, Kaizen, Genchi Genbutsu.


This Lean process improvement training course will enable an entire organisation to holistically apply Lean thinking and solutions across every aspect of their value stream. From the newest staffer to the CEO, the constant reevaluation of the value stream across each product and service family will challenge old thinking and create a new culture of Lean thinking. Once the value of a product or service is identified, then unnecessary waste can be removed with continual process improvement implementation.


Lean is not just limited to manufacturing and production, but also can be equally applied to service-oriented industries like healthcare, government, education and agribusiness.


Course Outline for Lean Process Improvement

Topic 1
Course Overview
  • Course Objectives
Topic 2
Understanding Lean
  • Participants will learn what Lean is and what its origins are. This session will explore the Toyota Precepts, how Lean differs from Six Sigma, and some common Lean terms.
Topic 3
The Toyota Production System
  • Participants will learn about the Toyota Production System House. Discover an alternate representation of the Toyota Production System.
Topic 4
The Toyota Production System House
  • The Toyota Production System House
Topic 5
The Five Critical Improvement Concepts
  • Discuss five key ideas supporting Lean process improvement: value, waste, variation, complexity, and continuous improvement.
Topic 6
Understanding Value with the Kano Model
  • This session will explore value with the Kano model, which divides product or system characteristics into three groups: basic, performance, and value added.
Topic 7
Types of Waste
  • In this session participants learn about the three main wastes (muda, muri, and mura) as well as some new types.
Topic 8
Creating a Lean Enterprise
  • Explore some ways to create an environmentally friendly organisation with Lean. Learn about the 20 keys to a Lean organisation.
Topic 9
The Plan, Do, Study, Act (PDSA) Cycle
  • The first session of Day Two will cover the PDSA cycle, which should be used to plan and implement organisational changes.
Topic 10
Using the R-DMAIC-S Model
  • This session will cover the Recognise - Define - Measure - Analyse - Improve - Control – Sustain model, an advanced version of PDSA primarily used in Six Sigma.
Topic 11
Lean Thinking Tools
  • Learn about some Lean thinking tools, including 5W-2H, Genchi Genbutsu, Gemba, and 5-S.
Topic 12
Kaizen Events
  • This session will cover the five levels of Kaizen events, with a focus on Level 3 (the Kaizen blitz).
Topic 13
Data Gathering and Mapping
  • Most of the second afternoon will be spent learning about and practicing various Lean data tools, including flow charts, Ishikawa (cause and effect or fishbone) diagrams, SIPOC charts, and value stream maps. We will also share some tips for effective data analysis.
Topic 14
A Plan to Take Home
  • The final session will challenge participants to think about roadblocks and pitfalls to Lean implementation and how to bring those lessons to their organisation. Participants will also be given some ideas for Lean projects and a framework for a successful Lean approach.
Topic 15
Workshop Wrap-Up
  • Participants will have an opportunity to ask questions and fill out an action plan

In-House Training - We’ll focus on what matters most to you and tailor to your context

Face-to-Face, Live Online, or Hybrid Class Tailored to Your Needs

When you want a tailored learning experience targeting exactly what you want without bringing everyone physically together, the best choice is a Live Online Class run by PDT.

We tailor the content and activities to be specific to your current needs and the needs of the people and run the course in our usual activity-based workshop style training, however, the participants can all be offsite, or some can be in the room with others offsite.

Unless you have a preferred tools we use 'Zoom for Education' that includes enhanced collaboration features such as One-click content sharing, real-time co-annotation (people can work together in activity files), and digital whiteboarding, we also include things like live polls and group chats so you virtually have the same collaborative learning experience of attending a course in a room with other people.

live online & hybrid

We have delivered these 100's (if not 1000's) of times, and get great outcomes. We achieve great outcomes because we keep our learner centric approach - just because it’s delivered through a screen to some or all participants doesn’t mean it needs to be less tailored or less personalised.

You still have an expert trainer who talks to you prior to the session and tailors the delivery to use your terminology, ensure activities are relevant and directly applicable and ensures an engaging learning experience that provide people with skills and techniques they can apply the very next day.

A hybrid class is with some people connecting online, and some people physically together in the same room.

Live Online Participant Feedback:

90% Overall Trainer Rating

88% Delivery was Adapted to me Personally

75% I Would Recommend this Course to Someone Else

Face to Face Options With Everyone in the same room

1-hour Motivator
one hour motivator
3-hour Power Sessions
3 hour power session
Full-day training
full day training
At your workplace At your workplace
In our Training Rooms In our Training Rooms
 In our Online Training  Room - the HIVE In our Online Training Room

We’ll make things easier so you can focus on adding more value

PDT Training Management Centre Logo

We provide the Training Management Centre which is an information hub before, during and after training.
(Let us know if there’s parts you don’t want to use)

Invites people to training

(So you don’t have to)

Invite People icon

Generates Sign in Sheet

(So you don’t have to)

Generate Sign In Sheet Icon

Generates Branded Flyer

If you want to ‘promote’ internally

Generate Branded Flyer Example

PDF’s of Certificates

(can be co-branded with your logo)

Completion Certificate Included

Collects and Reports feedback

(So you don’t have to)

Feedback Report Example

Complete Results Dashboard

(including trainer insights)

Results Dashboard Example

What are people going to do differently?

At the completion of training participants are encouraged to create an action plan, and invite an accountability buddy via their Orgmenta App.

In your Training Management Centre you have transparency to the action plans so you can see what people are going to do differently.

My Action Plan
Participants encouraged to create

Want to get clear on impacts and measure success? Our system and expert consultants support you.

Our systems and people make it easy to identify how you’ll be able to measure impacts,
and then report on the success in the weeks or months after training.

Measure metrics your way

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Training APIs

It’s surprisingly easy to make it so that your system can automatically be up to date with all the training record details you need.

More than just a training provider - we are your Learning and Development Partner, we look forward to working with you, talk to one of our friendly expert consultants today.

Outstanding learning that people can do in the flow of work

  • Fresh targeted video-based microlearning content with interactive lessons and quizzes included.
  • Rigourous review process
  • Only $11.00 per course per person per year.
  • Or get the $110.00 bundle and save.
Bite Size learning that people love
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