INTRODUCTION FOR LEAN MANUFACTURING WITH ARTIFICIAL INTELLIGENCE (AI) INTEGRATION (SMART LEAN)
In today’s rapidly evolving manufacturing landscape, staying competitive means going beyond traditional process improvement. Lean Manufacturing remains a proven framework for eliminating waste and delivering value—but when combined with Artificial Intelligence (AI), it becomes a powerful engine for smarter, faster, and more responsive operations.
This two-day hands-on training is designed to bridge the gap between Lean thinking and digital innovation. Participants will first build a solid foundation in Lean principles and tools, then explore how AI technologies—such as predictive maintenance and intelligent forecasting—can be integrated to enhance Lean initiatives.
Through interactive workshops, simulations, and real-world case studies, participants will gain practical skills and insights they can immediately apply to drive continuous improvement and digital transformation in their own operations.
LEARNING OBJECTIVES
- Understand Core Lean Manufacturing Principles
Learn the foundational principles of Lean (e.g., value, waste elimination, flow, pull, and continuous improvement) and how they apply to modern manufacturing environments. - Identify and Analyze Operational Waste
Develop the ability to identify the 8 types of waste (Muda) in manufacturing processes and apply Lean tools like 5S, Kaizen, and Value Stream Mapping to reduce inefficiencies. - Gain a Practical Understanding of AI in Manufacturing
Explore the fundamentals of artificial intelligence and machine learning, including how they function and the types of manufacturing problems they can solve. - Integrate AI Technologies with Lean Strategies
Discover how AI tools such as predictive maintenance, computer vision, and demand forecasting can be embedded into Lean processes to enhance performance and drive smarter decision-making. - Develop a Lean + AI Implementation
Create a tailored action plan to integrate AI within existing Lean initiatives, identifying pilot projects, success metrics, and strategies for scalable digital transformation.
LEARINING METHODOLOGY
This course is built around hands-on, experiential learning, combining real-world simulations, interactive workshops, and collaborative exercises to ensure practical understanding and skill development.
- Interactive Workshops
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- Apply Lean tools (e.g., Value Stream Mapping, 5S, Kaizen) to real or simulated manufacturing processes
- Collaboratively solve problems and brainstorm waste-reduction strategies
- Develop AI integration roadmaps based on Lean priorities
- Simulation Activities
- Realistic, scenario-based simulations
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- Visualize and analyze manufacturing flows
- Experience the impact of waste, variability, and poor flow
- Test AI-enhanced solutions like predictive maintenance or demand forecasting in a controlled environment – simulation workshop
- Data-Driven Exercises
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- Explore predictive models (e.g., for machine failure or demand patterns)
- Understand how AI models learn from process data
- Compare traditional Lean analysis with AI-supported insights
- Action Planning
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- Design – AI project for their organization (option)
- Present their integration strategy, including KPIs, tools, and expected impact
- Receive feedback from peers and instructors
WHO SHOULD ATTEND
- Manufacturing managers and engineers
- Lean practitioners and process improvement professionals
- Digital transformation leads and operations directors
- Anyone interested in Smart Manufacturing and AI in Industry 4.0
COURSE CONTENTS
Mastering Lean Manufacturing
Session 1: Introduction to Lean Thinking
- History and evolution of Lean
- The 5 Lean Principles: Value, Value Stream, Flow, Pull, Perfection
- Benefits of Lean in modern manufacturing
Session 2: The 8 Wastes (Muda) in Manufacturing
- Overproduction, Inventory, Motion, Waiting, Transport, Overprocessing, Defects, Unused Talent
- How each type of waste impacts cost and customer value
Session 3: Lean Tools & Techniques
- 5S, Kaizen, Kanban, Standard Work
- Value Stream Mapping (VSM)
- Visual management and Gemba walks
Session 4: Quality and Flow in Lean Systems
- Continuous flow vs. batch production
- Poka-Yoke (error-proofing)
- Lean quality systems (e.g., Jidoka, Andon)
Session 5: Lean Metrics & Continuous Improvement
- Key metrics: Lead Time, Takt Time, Cycle Time, OEE
- PDCA (Plan-Do-Check-Act)
- Building a culture of Kaizen
Integrating AI with Lean Practices
Session 6: AI Overview for Manufacturing Professionals
- What is AI? What is machine learning?
- AI vs traditional automation
- Relevance of AI to Lean objectives
Session 7: AI for Predictive Maintenance
- TPM + AI = Predictive Maintenance
- Using sensors and ML to predict machine failures
- Reducing waiting, downtime, and excess inventory
Session 8: AI in Quality Inspection
- Vision systems for defect detection
- AI to reduce rework and scrap (Lean waste: Defects)
- Feedback loops to upstream processes
Session 9: AI for Inventory Optimization & Demand Forecasting
- How ML improves JIT and Pull systems
- AI demand forecasting vs Excel forecasting
- Reducing overproduction and excess stock
Session 10: AI-Driven Root Cause Analysis & Lean Kaizen
- Using AI for fast RCA (automated pattern discovery)
- Augmenting 5 Whys and Fishbone with AI insights
- AI-enhanced Kaizen events
Session 11: Build a Lean + AI Roadmap
- How to start small: pilot projects and ROI
- Tools & platforms to explore
- Aligning Lean goals with digital transformation
Upgrade Your Manufacturing Game with Smart Lean! Lean + AI = Smarter, Faster, Leaner Operations.
