Lean and Operational Excellence Corporate Training
Remove waste, stabilize processes, and make safe operation part of everyday work.
Edstellar's instructor-led Lean & Operational Excellence training helps operations teams cut waste, stabilize flow, and hardwire safety into daily routines. Your team builds hands-on skills in value stream mapping, 5S, standard work, kaizen events, A3 problem solving, and error-proofing through guided labs.
Instructor-led group trainingVirtual / on-site / off-site10 languagesDelivered inEnglish, Spanish, Mandarin, German, Arabic, Portuguese, Hindi, French, Japanese, Italian100+ countriesWe have delivered inUnited States, United Kingdom, India, Canada, Germany, France, Netherlands, UAE, Saudi Arabia, Singapore, Australia, Japan, Brazil, South Africa and 90+ more countries
How we build a lean, safe operations team
The Edstellar LEAN & OPERATIONAL EXCELLENCE Capability Model
Diagnose
Map waste and process pain points in your current operations before training.
Standardize
Align on 5S, standard work, and visual management rules across teams.
Practice
Run guided labs: value stream mapping, 5S audits, and kaizen drills.
Measure
Track cycle time, defect rates, and safety incidents against targets.
Scale
Roll out lean routines and huddles across every shift and site.
Need more than one program?Get a group quote
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Program Overview: What is Lean and Operational Excellence?
Lean & Operational Excellence is an instructor-led program for operations, maintenance, and safety teams that want smoother flow and fewer incidents. Your team learns the core lean toolkit: spotting the eight wastes, mapping value streams, running 5S, designing standard work, leading kaizen events, and solving problems with A3s. Every concept is tied to safety outcomes, and the program closes with a capstone lean safety transformation plan for your site.
Training pairs concise lean instruction with hands-on labs on your own processes. Learners map a real value stream, run a 5S exercise, draft standard work, and lead a simulated kaizen event with instructor coaching at every step. A3 problem solving is practiced on actual recurring incidents, with coaches reviewing each A3 for rigor. The program ends with the capstone, where teams design the full lean safety transformation for their operation.
Waste and risk travel together: messy workplaces hide hazards, unstable processes create rework and injuries, and firefighting becomes the operating system. Teams try lean as a poster campaign and nothing changes. This program makes lean real by grounding every tool in the work your teams do, so improvement sticks and incidents fall.
The capstone is a complete lean safety transformation plan for the team's own site. It includes the value stream map with waste targets, the 5S and standard work rollout, the kaizen calendar, the A3 pipeline for recurring incidents, and the tiered huddle structure to sustain it. Presented to the cohort and refined with instructor feedback, the plan goes back as a working blueprint, the difference between a lean workshop people forget and a transformation that keeps compounding.
Six modules and 24 hours: lean foundations, value stream mapping, 5S and standard work, kaizen and A3s, hoshin kanri with tiered huddles, and a capstone transformation plan. Every module pairs concepts with a guided lab. It closes with a capstone plan your team designs, costs, and presents.
What's Included in this Workshop for Your Enterprise Teams
- 1
Waste walks
Spot the eight wastes on your own processes and lines.
- 2
Value stream mapping
Map current-state flow and design a future-state map.
- 3
5S audits
Score work areas and design a sustain plan.
- 4
A3 problem solving
Frame a real problem and run root cause analysis.
- 5
Capstone plan build
Design and present a 90-day lean safety plan.
- Instructor-led delivery across virtual, onsite, and hybrid
- Guided labs in every module with instructor coaching
- Capstone lean transformation plan, reviewed with your team
- Flexible scheduling around your calendar
- Lab guides and improvement templates included
- Group size and batches set along with you
Build your team's skills. Anywhere in the world.
Real-world use cases
from day one
Instructor-led training
for your teams
Delivered globally
in 100+ countries
Enterprise Training Solutions Customized for Your Company
One partner for instructor-led corporate training, delivered the way your teams work.
Request a Training Quote- Customized Training Delivery
- Scale Your Training: Small to Large Teams
- In-person Onsite, Live Virtual or Hybrid Training Modes
- Plan from 2000+ Industry-ready Training Programs
- Hands-On Labs on Live Infrastructure, Led by Industry Experts
Lean and Operational Excellence Course Topics and Program Outline
Six modules take your team from lean foundations to a defended 90-day lean safety transformation plan.
Built by Edstellar with lean practitioners
Built by practitioners who run lean transformations in production, shaped around your processes and use cases.
We benchmark your team's process maturity, waste levels, and safety performance before training begins.
Instructor-led sessions cover lean foundations, value stream mapping, and 5S with live operational examples.
Guided labs: map value streams, audit 5S workplaces, run kaizen drills, and solve problems with A3s.
Your team builds a capstone transformation plan: a 90-day lean safety roadmap with metrics and reviews.
Hands-on throughout: guided lean labs in every module, closing with a capstone transformation plan.
Delivered as
Hybrid delivery across virtual and onsite sessions, scheduled around your calendar. Cohorts train as one group or split into batches.
Run a waste walk on your own processes and log the eight wastes.
learna)The eight wastes in operations and office work
b)Lean thinking and flow over batching
c)Safety as a non-negotiable lean outcome
d)Mapping your team's biggest improvement opportunities
Draw a current-state map of one end-to-end flow with data boxes.
learna)Current-state mapping symbols and data boxes
b)Takt time, cycle time, and lead time math
c)Spotting bottlenecks and safety risks in the stream
d)Designing a future-state map with pull
Audit a simulated work area with a 5S scorecard and design the sustain plan.
practicea)Sort, set in order, shine, standardize, sustain
b)Visual controls, shadow boards, and andon signals
c)Writing standard work for safety-critical tasks
d)Layered audits that keep 5S alive
Run a mini kaizen event: scope a problem, analyze causes, and test countermeasures.
practicea)Planning and running a kaizen event
b)A3 thinking: background, analysis, countermeasures
c)Root cause analysis with 5 whys and fishbone
d)Error-proofing (poka-yoke) for critical steps
Draft a hoshin X-matrix and a tiered huddle cadence for one value stream.
applya)Hoshin kanri: aligning goals from site to team
b)Tiered daily huddles and escalation rules
c)TPM basics: autonomous care and planned maintenance
d)Lean metrics: OEE, first-pass yield, incident rates
Build, cost, and present a 90-day lean transformation plan for your own operations.
applya)Selecting the pilot value stream and scope
b)Building the 90-day improvement roadmap
c)Costing benefits and safety gains
d)Presenting the plan and defending it in review
Customize this program tailored to your team?
Tell us your training needs: what your team already works with, the level they’re at, and the topics you want them to focus on. We’ll adjust the modules, duration and hands-on labs, and send you a customized outline for your group.
Key Skills and Outcomes Your Team Will Gain
After 24 hours of guided practice, your team can spot waste, map value streams, sustain 5S workplaces, run kaizen events, solve problems with A3s, and align improvement work to business goals.
Spot the eight wastes
Identify motion, waiting, defects, and other wastes in your processes.
Map value streams
Draw current-state and future-state maps with takt and lead time data.
Run 5S audits
Score workplaces with 5S checklists and sustain improvements over time.
Write standard work
Document best-known methods for safety-critical and routine tasks.
Lead kaizen events
Scope, facilitate, and follow through on rapid improvement events.
Solve problems with A3s
Apply structured problem solving from background to countermeasures.
Align goals with hoshin
Connect daily improvement work to site-level objectives and metrics.
Teams that Benefit from this Lean and Operational Excellence Group Training
This group training is built for operations, maintenance, and safety groups that want smoother flow and fewer incidents. It suits teams new to lean as well as teams refreshing stalled programs. Content adapts to each cohort's roles and experience so every team practices the workflows it owns.
Stabilize flow and cut waste on the line
Production and operations teams that own throughput, quality, and schedule adherence.
Workflow friction
- Unstable processes and firefighting
- Hidden waste across shifts
- Improvement efforts that stall
How the program helps
- Faster, steadier production flow
- Fewer defects and rework loops
- Clear daily performance targets
Practice use cases
- value stream mapping
- kaizen events
- 5S audits
- standard work
Reduce breakdowns with TPM discipline
Maintenance and reliability teams that keep equipment available and safe.
Workflow friction
- Reactive breakdown culture
- Unplanned downtime losses
- Spare parts disorganization
How the program helps
- Higher equipment availability
- Planned maintenance routines
- Faster, safer repairs
Practice use cases
- tpm basics
- autonomous care
- visual management
Hardwire safety into lean routines
EHS teams that must cut incident rates while operations improve productivity.
Workflow friction
- Safety seen as separate from lean
- Incident repeat causes
- Weak follow-up on actions
How the program helps
- Safety built into standard work
- Fewer incidents and near misses
- Audit-ready improvement records
Practice use cases
- error proofing
- safety gemba walks
- A3 problem solving
Coach teams and sustain the gains
CI practitioners who facilitate improvement work and coach frontline teams.
Workflow friction
- Facilitation skill gaps
- Gains that fade over time
- Low frontline engagement
How the program helps
- Stronger kaizen facilitation
- Sustained improvement culture
- Visible savings and safety gains
Practice use cases
- hoshin kanri
- tiered huddles
- coaching kata
Cohorts train as a cross-functional workforce, with each small group aligned on shared operational and safety standards.
Prerequisites: This training benefits operations, maintenance, safety, and continuous improvement teams. No prior lean experience is required; curiosity about how work actually flows is enough. Teams already running lean programs can use the labs to sharpen facilitation and restart stalled efforts. We adapt examples and labs to your processes, equipment, and sites.
Operator to Improvement Leader
Operators and technicians build foundational lean habits; supervisors and CI practitioners advance to leading kaizen events and aligning improvement work to site goals.
A program that grows with operations careers, from lean basics to confident, self-led improvement.
Mixed cohort, or several teams at once?
We can tailor the training to different teams, roles, and experience levels within the same program.
Certificate of Training Completion.
On successful completion, employees receive an Edstellar course completion certificate, recognizing their commitment to ongoing learning and professional development. It validates the skills they have built and motivates them to keep growing and contribute to organizational success.
Earned, not attended. Awarded on completion of all hands-on labs and the capstone project.
Training Delivery Modes: Virtual, Onsite and Hybrid
Instructor-led delivery in the format that fits your teams and sites, with the same guided labs in every mode.
Hybrid Training
Split delivery: theory live online, guided labs onsite at your facilities for maximum relevance.
- Online sessions for concepts and planning
- Onsite labs using your real processes
- Same instructor across both formats
- One capstone plan for the whole cohort
Onsite Training
Delivered at your facilities so waste walks, 5S audits, and kaizen drills use your real work areas.
- Labs run on your shop floor
- Gemba walks with your teams
- Customized to your equipment
- Batch scheduling for shifts
Live Virtual Training
Fully live online delivery with digital boards, breakout rooms, and the same guided lab sequence.
- Live instructor in every session
- Digital value stream mapping tools
- Breakout labs in small groups
- Same capstone plan deliverable
Need a training format that works for your team?
Full days, half days across weeks, or split by module. Tell us the delivery window and we schedule the cohort around it.
Learn from industry experts.
Every session is led by a practitioner who has run monitoring for models in production, not a generalist working from slides.
Abhishek
7 QC Tools Trainer in Visakhapatnam
13+ years of Experience
Shrikrishna
Lean Six Sigma White Belt Trainer in Pune
29+ years of Experience
Prasad
Machine Learning Trainer in Mumbai
16+ years of Experience
Vineet
Quality Management System (QMS) Trainer in Kanpur
15+ years of Experience
Ravinder
Quality Management Trainer in Pune
14+ years of Experience
Sivanesan
PMP & PMI-ACP Trainer in Chennai
11+ years of Experience
Shyam
ISO 9001 Lead Auditor Trainer in Chennai
15+ years of Experience
Trainers are matched to your stack and delivery window at scheduling. We confirm your assigned trainer, with a full profile, before the program is booked.
Frequently Asked Questions
Share your team size, sites, and dates and we send a tailored quote with batch options.
Yes. A short call with a training advisor maps your goals, processes, and the right program scope.
Yes. Live virtual sessions include the same guided labs, with digital boards and breakout rooms.
Yes. Onsite delivery runs at your facilities so labs can use your real processes and work areas.
24 hours of instructor-led training across six modules, usually run over three to four days.
Question not answered here?
Put it in the request. A training specialist answers it directly, within one business day.
Where this Training Fits in Your Team's learning path.
Lean and operational excellence builds on a White Belt introduction to improvement terms. Your team then applies lean principles across operations, maps value streams to find where flow breaks down, and finally learns to lead improvement as an ongoing discipline.
Why Choose Edstellar as Your Lean and Operational Excellence Training Provider
Edstellar delivers instructor-led corporate training for operations teams, shaped around your processes, equipment, and safety priorities.
EXPERT TRAINERS
YEARS DELIVERING
ORGANIZATIONS TRAINED
CERTIFIED
Tailored
Programs shaped around your processes, equipment, and sites, so every lab mirrors your real work.
Proven Methodology
A field-tested curriculum sequence from waste walks to hoshin alignment, refined across industries.
Practice-Based Learning
Guided labs in every module: maps, audits, kaizen drills, and A3s, coached by lean practitioners.
Expert Trainers
Practitioners who run lean transformations in production, matched to your team's processes.
Global Scale
Consistent delivery across sites and regions, with batch schedules that fit shift calendars.
Measurable Outcomes
Track flow time, defect rates, and incident reductions against the targets set in training.
Also from Edstellar
Talent assessments
Psychometric, behavioral, leadership and 360-degree assessment.
→Training needs analysis
Needs analysis, gap identification, and a training roadmap.
→L&D consulting
Learning strategy, content, technology and ROI measurement.
→OD consulting
Org design, succession planning and cultural change.
→Managed training services
Training outsourcing, vendor management, logistics and administration.
→Coaching solutions
Executive and manager coaching that keeps skills in use.
Start an RFP shaped to your needs.
Answer three quick questions about team size, scope, and how often you need the program run, then send the request from the last step. Everything you choose travels with it, so you only fill this in once.
How many team members need training?
Lean & Operational Excellence Training Packages & Pricing
Where L&D holds an annual budget, license packages price the whole year at once instead of raising a purchase order per workshop. Hours and licenses are pooled across teams, programs and locations, so unused capacity is not stranded in one department.
Starter
120
trainee licenses64 hours of group training
Tailored for SMBs
Growth
320
trainee licenses160 hours of group training
Ideal for growing SMBs
Enterprise
800
trainee licenses400 hours of group training
Designed for large corporations
Custom
Unlimited
trainee licensesDuration set by the rollout
Multi-region and multi-year
Training Packages & Pricing
Choose the training format that works for your team. Pricing is customized based on your requirements, cohort size, and delivery needs.
Request Lean and Operational Excellence Training for Your Team
Share your team size, sites, processes, and timelines to receive a tailored training plan with batch options.