Kaizen Training & Certification Programs

Learn about our lean manufacturing and kaizen training certification programs

Shinka Management provides lean manufacturing and kaizen training certification programs delivered on-site, online and as Japan-based immersion programs.

Lean Leadership Master Class

Delivery: On-site, Online | Format: 2 days (on-site) or 3 sessions (online) | Suited to: Middle to Senior Management

The Lean Leadership Master Class is designed for middle and senior managers, lean consultants and lean practitioners who are interested in fostering a culture of continuous improvement within their organization. The training is led by Hyodo Sensei, a former factory manager and director at the Toyota factory in Japan responsible for the manufacture of the HiAce vehicle. Hyodo Sensei shares his experience leading the Toyota Production System and teaches participants the tools, mindset and leadership practices required to implement and sustain a culture of continuous improvement. This kaizen training program is typically run as a two-day on-site course including a facility tour and analysis at a local company, or through three shorter sessions when run online, including a video-based factory tour.

Lean Implementation Master Class

Delivery: On-site, Online | Format: 2 days (on-site) or 3 sessions (online) | Suited to: Middle to Senior Management

This kaizen training program teaches the key practices required to implement lean manufacturing practices within your operations. The kaizen training goes beyond theory, including lean implementation case studies from companies in Japan and abroad, accompanied by many photo and video examples. The program brings together Shinka Management’s core theory and case studies relating to the Toyota Production System, 5S, Standard Work and Visual Management, together with coverage of poka-yoke, kanban and improvement suggestion schemes. Three video factory tours are also provided of facilities in Japan to demonstrate key theory and concepts covered.

Although there is some cross-over between topics, this program complements the learnings from the Lean Leadership Master Class as it has a strong focus on translating theory into practice. It is recommended that both these programs be undertaken, with a gap of a few months in between.

Lean Continuous Improvement

Delivery: On-site, Online | Format: Six 2-hour sessions | Suited to: Frontline staff and team leaders

This program engages employees over a six-week period, supporting them in developing knowledge of basic lean principles and an understanding of how to logically apply these principles to reduce mistakes, problems and waste in the work area. Workshops engage the employee once a week through interactive, consultant-led training, to understand the application of the knowledge and the opportunity to implement within their workplace.

This program is designed to help your organization involve all employees on your lean journey. Outcomes include improvements in safety, quality, cost and customer service.

A complete course breakdown can be found on the Lean Continuous Improvement page.

5S Master Class

Delivery: On-site, Online | Format: 1 full day | Suited to: All levels

Successful lean companies consider 5S the basis for all improvement. 5S implementation sets in place standards and rules that are critical for higher level improvement activities and innovations. It heightens the awareness of all employees in regards to safety, quality, efficiency, cost and time, and contributes to reducing waste through visual control, error-proofing and decreasing the frequency of equipment breakdowns that impact on quality, efficiency and cost reduction.

This one-day master class covers 5S theory together with examples from some of the leading lean organizations in the world. Take away ideas, strategies and templates that will assist in strengthening your organization’s kaizen foundations.

Standard Work Master Class

Delivery: On-site, Online | Format: 1 full day | Suited to: All levels

Standard work is considered one of the key foundations for all kaizen and lean management activities in Japan, allowing operations to be quantified, managed and improved. It is critical to establish standard work in order to guarantee efficiency, quality, cost, delivery and safety within your operations. Importantly, standard work also provides a clear baseline for further improvement to be identified and achieved.

This one-day master class strengthens participants ability to analyze and create standard work within their operations. Participants learn how standard work is defined in lean manufacturing best-practice companies such as Toyota, and learn about the role of time studies and work sampling for defining standard work and identifying improvement opportunities.

Visual Management Master Class

Delivery: On-site, Online | Format: 1 full day | Suited to: All levels

Visual Management is considered one of the key foundations for all kaizen and lean management activities in Japan, allowing issues to quickly be identified and addressed. The process of kaizen cannot begin in a workplace without first uncovering issues. Making issues visual empowers your workforce to identify when and where the issues occur allowing action to be taken in a timely manner. Further, significant improvements can be realized through simply visualizing the current state of operations and increasing employee awareness.

Through participating in this one-day master class, participants learn how visualization of a workplace can become a powerful management tool. Participants learn through examples from some of the leading lean organizations in the world – including Toyota. This kaizen training course provides ideas and strategies that will assist in strengthening your organization’s foundations for continuous improvement.

TPM Master Class

Delivery: On-site, Online | Format: 1 full day | Suited to: Middle to Senior Management

Total Productive Maintenance programs help staff across an organization to maximize the function and efficiency of equipment and the production system in order to improve productivity and quality, and reduce cost. Effective TPM programs lead to a reduction in equipment breakdowns, quality defects and claims, and accidents. Productivity is typically boosted and labor costs trimmed. Higher reliability in equipment and processes resulting from TPM programs also allow organizations to reduce inventory levels.

The TPM masterclass covers the principles and practices of Total Productive Maintenance as taught and implemented in Japan. Numerous examples from Japanese industry are included in the form of case studies, videos and photos.

Lean Japan Tour

Delivery: Japan immersion program | Format: 1 week | Suited to: Middle to Senior Management, Lean Trainers and Consultants

The Lean Japan Tour is Shinka Management’s flagship lean professional development program. Held in Japan several times annually, this full immersion program includes lean seminars run by former Toyota factory managers, several visits to benchmark lean companies and hands-on practical kaizen training. Participants return home with a strong understanding of how a lean culture can be implemented and sustained across their organization.

For full details of this program, see Lean Japan Tour.

Japan Kaizen Training

Delivery: Japan immersion program | Format: 5 days | Suited to: Team leaders, supervisors and middle management

The Japan Kaizen Training week is an opportunity to experience kaizen at its source. Participants are trained within a Toyota Group training facility throughout the duration of the week with a mix of theory, practical training and factory visits.

The Japan Kaizen Training program is similar in nature to our Lean Japan Tour offering. It is tailored to suit staff responsible for implementing lean practices at the front line, and includes a greater emphasis on practical implementation, and less emphasis on corporate strategy and lean program design. The program is typically run for individual companies and corporate groups, and can be customized to suit their individuals requirements, including timing and length of program.

Up-coming Lean and Kaizen Training Programs

For further information and registration, please view the individual event page from the list of kaizen training events below. A general overview of our training offering can also be found on our lean training page.