Lean Management – Green Belt

Organizations across Abu Dhabi and the wider region are working to streamline operations, reduce inefficiencies, and build systems that respond predictably to demand. Capacity Planning plays a central role in this shift. It helps decision-makers understand how resources are used, where constraints appear, and how processes can be strengthened without unnecessary cost or delays.

This training framework introduces the essential concepts behind Capacity Planning and Lean Management, giving participants practical methods to evaluate workflows, improve operational flow, and build systems that support continuous improvement.

Who This Learning Path Is Designed For

The content supports professionals involved in operational decisions, process performance, or continuous improvement roles, including:

• Managers and Supervisors
• Executives and Team Leaders
• Quality Personnel
• Manufacturing and Industrial Engineers
• Floor-Level and Process Staff
• The learning structure is suitable for participants who are new to Lean concepts or those looking to deepen existing knowledge.

Course Outline

This Capacity Planning & Lean Management Training is structured as a practical, concept-to-application learning program focused on operational efficiency and continuous improvement. Through a progressive framework, participants move from capacity analysis and bottleneck identification to Lean principles, Toyota Production System concepts, and workplace improvement tools—developing the capability to evaluate processes, balance resources, and implement sustainable performance improvements across operational environments.

Module 1 – Operations Management and Capacity Planning

This module examines how organizations plan and measure their operational capabilities:

• Understanding the Supply Chain SCOR model
• SCOR attributes related to capacity alignment
• Determinants of effective capacity
• Key decisions in production capacity planning
• Identifying bottlenecks and evaluating required investments
• Methods for determining capacity
• Work order scheduling approaches
• Load leveling methods
• OEE (Overall Equipment Effectiveness) fundamentals

Module 2 – Foundations of Lean Management

A structured introduction to Lean thinking and its influence on modern operations:

• The purpose and evolution of Lean
• Historical background and origins
• Toyota Production System (TPS) overview
• The Toyota Precepts and their relevance to workplace discipline and flow

Module 3 – Liker’s Toyota Way Framework

A deeper look into the well-known four pillars of the Toyota Way:

• Philosophy and long-term thinking
• Process design for reliability and flow
• People and partner development
• Problem-solving as a cultural practice

Module 4 – The TPS House Structure

Participants explore how TPS integrates stability, flow, and error prevention:

• Core goals of the Toyota Production System
• Just-In-Time (JIT) as a planning philosophy
• Jidoka and error-free production concepts
• Kaizen as a continuous improvement engine
• Foundational principles that support the TPS House

Module 5 – Five Guiding Principles of Lean Business

A step-by-step exploration of Lean implementation:

• Value identification using the Kano Model
• Value Stream Mapping and Waste Identification
• Flow and the causes of operational interruption
• Pull-based systems for reducing unnecessary activity
• Continuous improvement through sustained refinement

Module 6 – Improvement Tools and Workplace Practices

A practical toolkit for diagnosing processes and initiating improvement cycles:

• Gemba: direct observation at the workplace
• Genchi Genbutsu: understanding issues at the source
• Womack’s Lean principles
• Kaizen practices for structured, incremental change

Methodology

This training approach uses a blended practical framework designed to help participants internalize operational concepts through real-world application:

• Conceptual Understanding – Each topic is introduced with simple, clear explanations to build strong foundational knowledge.
• Process Analysis Exercises – Participants examine sample workflows, identify bottlenecks, and classify process wastes.
• Hands-On Demonstrations – Tools such as scheduling methods, OEE calculations, bottleneck mapping, and basic Lean diagnostics are applied to simulated scenarios.
• Reflective Practice – Each module includes short analytical tasks that encourage participants to link concepts to their own workplace context.
• Progressive Learning Structure – Modules are arranged from foundational principles to practical tools, ensuring participants gain operational clarity before applying improvement techniques.