IMPROVE YOUR PROCESSES &

Optimize Operations

Process Optimization Banner

Process optimization helps organizations work smarter, faster, and more efficiently—driving higher quality, lower costs and better customer outcomes. Industry Extension Services training equips leaders and teams with proven methods to eliminate waste, improve flow and solve problems at the root cause. By building these capabilities, organizations create a culture of continuous improvement that boosts productivity, strengthens performance and delivers lasting competitive advantage.

LEAN Training
Lean Processes

Lean is a proven methodology that focuses on enhancing “real work” — the activities and services that add value to your organization through eliminating waste, improving flow and heightening the customer experience—and fundamentally changing how people throughout your organization think, approach problems and tackle daily challenges.

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Lean 100

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Introductory Overview

Lean 100 is a one day overview designed specifically for manufacturers. This course will introduce participants to the lean philosophy and the application of basic lean tools.

Participants will:

  • Learn the basics behind Lean Manufacturing
  • Experience a hands-on simulation to better understand and utilize Lean concepts
  • Topics covered:

  • Principles of Lean Thinking
  • Value-Add versus Non-Value-Add
  • 8 Wastes
  • Value Stream Mapping
  • 5S/Visual Management
  • Standard Work
  • Quality at the Source
  • Pull Systems
  • Kaizen
  • Duration:

    7-8 Hours | 1 Day

    Format:

    Customized in-person, on-site

    Recommended For:

    All levels of production managers, engineers, line supervisors, work team members and production workers.

    Contact your Regional Manager to schedule.

    Lean 200

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    Applying the Fundamentals

    Lean 200 is a two-day, hands-on course that equips participants with practical tools to drive lasting organizational improvement through an interactive industry simulation.

    Participants will:

  • Identify and apply the basic lean tools
  • Recognize improvements within their work areas through communication, morale and quality  improvements
  • Benchmark other organizations throughout North Carolina
  • Topics covered:

  • Value Stream Mapping
  • 5S
  • Standard Work
  • A3 for problem-solving
  • Kaizen
  • Duration:

    14-16 Hours | 2 Days

    Format:

    Customized in-person, on-site

    Coaching:

    Customized implementation coaching services are available after course completion.

    Recommended For:

    Any professional interested in learning more about lean applications. No prior lean training or experience is required.

    Contact your Regional Manager to schedule.

    Lean 300

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    Facilitating Continuous Improvement

    Lean 300 is a three-day course that prepares participants to plan, lead and sustain successful kaizen events through hands-on facilitation training.

    Participants will:

  • Master kaizen fundamentals, best practices and common pitfalls
  • Understand the key elements of a Lean-driven culture
  • Learn to align Lean tools and facilitation with a strategic roadmap for continuous improvement
  • Topics covered:

  • Kaizen Rapid Improvement
  • Creating a Lean Support Structure
  • Kaizen Planning
  • Running a Kaizen Event
  • Post Kaizen Follow-up
  • Lean Culture
  • Kaizen Sustainability
  • Examples of Real Life kaizen Event
  • Duration:

    21-24 Hours | 3 Days

    Format:

    Customized in-person, on-site

    Coaching:

    Customized implementation coaching services are available after course completion.

    Recommended For:

    Any professional interested in learning more about lean applications within their industry who has completed Lean 200: Applying the Fundamentals.

    Contact your Regional Manager to schedule.

    Lean Transformation

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    Customized Transformations

    Because every organization is different, our Lean solutions are tailored to your needs—from short courses to multi-month programs with coaching and follow-up. Our goal is to create lasting cultural and performance change.

    Customized training to take your organization to the 

    Starting with the fundamentals of Lean, kaizen, and value stream mapping to begin leading continuous improvement.

    Topics covered:

  • Lean Fundamentals
  • 5S, visual management, standard work, A3 problem solving and leadership coaching
  • Deepen your capabilities through advanced tools, kaizen practices and an operations assessment to identify opportunities for improvement.

    Implement a full suite of Lean tools—including SMED, TPM, pull systems, work cells and Kata—with expert coaching and assessments.

    Duration:

    Fully customizable (see below)

    Format:

    Customized in-person

    Examples include

    Five-Day Lean Leader (35–40 hours)

    Learn the fundamentals of Lean, kaizen, and value stream mapping to begin leading continuous improvement.

    Ten-Day Lean Leader (70–80 hours)

    Expand your Lean toolkit with 5S, visual management, standard work, A3 problem solving and leadership coaching.

    Fifteen-Day Lean Leader (15 days)

    Deepen your capabilities through advanced tools, kaizen practices and an operations assessment to identify opportunities for improvement.

    Full Transformation (24–30 days)

    Implement a full suite of Lean tools—including SMED, TPM, pull systems, work cells and Kata—with expert coaching and assessments.

    Full Transformation with Facilitator Support (24–30+ days)

    A dedicated facilitator partners with your team to drive sustained improvement, align leadership and deliver measurable bottom-line results.

    Contact your Regional Manager to schedule.

    Lean Practitioner Certification & Coaching

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    A Lean Certificate is awarded upon successful completion of the project, evaluation by the Lean Certification Review Board, and verification of results by the participant’s supervisor or director.

    Program participants are continuous improvement professionals seeking to lead their organizations into the transformative culture of lean manufacturing. This program is an intellectually rigorous experience featuring one-on-one coaching, mentoring and learn-by-doing exercises. Program enrollment is limited to individuals who have successfully completed Lean 200 and 300.

    Participants will:

  • Collaborate with a Lean Coach on a real-world improvement project within their organization
  • Apply Value Stream Mapping, 5S and A3 problem-solving methodologies
  • Build the skills and confidence needed to support and lead Lean transformation initiatives
  • Coordinate and execute team events such as value stream mapping and kaizen activity
  • Determine product or process current state, future state and create an implementation plan for suggested change
  • Measure and report project results and improvements
  • Create personal growth plans to improve facilitation skills
  • Duration:

    Participants have up to 24 months to complete their in-house project.

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Professionals preparing to lead their organization’s Lean transformation who have completed both the  Lean 200 and Lean 300 courses and have successfully achieved a passing grade on the lean body of knowledge assessment.

    Contact your Regional Manager to schedule.

    Advanced Lean Practitioner Certification & Coaching

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    Our Advanced Lean Practitioners are continuous improvement leaders or executives seeking to tie their organization’s lean program into the overall organizational strategic plan through the transformative culture of Toyota Kata, Managing for Daily Improvement, and Hoshin Kanri. This program is an intellectually rigorous experience featuring one-on-one coaching, mentoring and learn-by-doing exercises. Program enrollment is limited to individuals who have successfully completed the Lean Practitioner Program.

    Participants will:

  • Foster a culture of scientific problem solving throughout the organization
  • Coordinate and execute lean strategy at the organizational level in an effort to ensure a successful strategic plan
  • Learn to find success through proactive lean measures versus reactive application of lean tools
  • Topics covered:

  • To successfully complete the program, participants must:
  • meet the attendance requirement,
  • obtain Prior Completion of NC State IES Lean Practitioner Certificate Program,
  •  complete three of the advanced modules (e.g. A3 Thinking, Toyota Kata, MDI, Lean Leader, Hoshin Kanri),
  • pass an exam based upon course learnings and body of knowledge and
  • complete a project that demonstrates understanding and application of advanced Lean tools and methodologies taught during modular coursework.
  • Duration:

  • 60 classroom hours (3 advanced modules) in addition to basic Lean Practitioner modules/requirements
  • Project completion and validation expected within 12 months
  • Format:

    Customized on-site

    Recommended For:

    Continuous improvement leaders or executives seeking to tie their organization’s lean program into the overall organizational strategic plan.

    Contact your Regional Manager to schedule.

    Lean Office

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    Lean Office is a foundational Lean course designed specifically for business and office environments. The program introduces participants to Lean philosophy and core tools for improving administrative and transactional processes. Through an electronic laptop-based simulation, participants apply Lean concepts in a realistic business setting to identify waste, improve flow and drive measurable process improvement.

    Participants will:

  • Learn the fundamentals of Lean thinking and continuous improvement
  • Participate in an interactive business process simulation
  • Build current- and future-state value stream maps using real case data
  • Topics covered:

  • The 8 Wastes
  • Value-Added vs. Non-Value-Added work
  • 5S and Standard Work
  • Value Stream Mapping
  • Kaizen
  • Duration:

    7–8 Hours | 1 Day

    Format:

    Customized on-site, in-person

    Recommended For:

    Business and office managers, engineers, supervisors, team members and professionals involved in administrative, service or transactional processes.

    Contact your Regional Manager to schedule.

    Lean Healthcare

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    Lean Healthcare will make your patients healthier, your employees happier and your organization more effective. We work with hospitals, public health, physician practices, home health, community care and community health.

    We also offer Lean Healthcare Certification to help support medical professionals who desire to help create and lead a culture of continuous improvement throughout their organization.

    Participants will:

  • Learn to run the clinic, office or hospital more efficiently with Lean Healthcare
  • Improve processes
  • Create value-added systems
  • Increase customer service and satisfaction
  • Topics covered:

  • On-site Lean training and workshops for healthcare teams
  • Strategic assessments and planning to guide your Lean transformation
  • Kaizen and value stream mapping facilitation
  • Lean coaching and mentoring
  • Duration:

    7–8 Hours  | 1 Day

    Format:

    Customized on-site, in-person instruction

    Coaching:

    Customized implementation coaching services are available after course completion.

    Recommended For:

    Hospital, public health, physician practices, home health, community care and community health professionals.

    Contact your Regional Manager to schedule.

    Lean Government, Non-Profit & Service Sector Applications

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    Lean Government helps public agencies identify and eliminate waste in administrative and service delivery processes, ensuring communities receive greater value for every dollar invested. Industry Expansion Solutions (IES) has partnered with municipalities and state agencies of all sizes to improve daily operations and address complex challenges through a culture of continuous improvement.

    Lean for Nonprofits for nonprofit organizations support rapid-cycle improvements that increase efficiency, enhance stakeholder engagement and improve service quality. By reducing errors, delays and non–value-added activities, organizations can achieve meaningful results through practical, low-cost solutions that prioritize creativity over capital.

    Lean for the Service Sector helps service-focused organizations—including customer service, sales and transactional teams—improve performance by streamlining workflows and strengthening communication. IES works with frontline staff and leadership through traditional and virtual Gemba walks to identify process gaps and uncover opportunities for sustainable operational improvement.

    Participants will:

  • Learn the Lean Model
  • Identify activities that add value to the customer
  • Establish the sequence of flow for the process (current state value stream)
  • Eliminate or reduce the activities that do not add value to the customer
  • Create a more organized workflow
  • Create a continuous improvement culture that strives to eliminate waste
  • Topics covered:

  • Educational and tool-based training programs for all levels of a client’s organization, including executives, directors, supervisors and front-line staff
  • On-site assessment of client lean needs
  • Creating a flexible business model for “Organizational Excellence using Lean Thinking” (transformation) in all types of government organizations (small/ medium/large)
  • Providing customized solutions to address gaps that clients experience in performance excellence
  • Duration:

    7–8 Hours  | 1 Day

    Format:

    Customized on-site, in-person instruction

    Coaching:

    Customized implementation coaching services are available after course completion.

    Recommended For:

    Government and non-profit organizations

    Contact your Regional Manager to schedule.

    Other Lean Training & Services

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    In addition to our core courses, we offer an extensive range of process optimization training designed to meet your organization’s unique needs. From Lean Kaizen and Lean Leadership to Effective Problem Solving, Root Cause Analysis, Facility Flow, Product Development and Robotics & Automation, our programs can be customized to help your teams improve processes, enhance productivity and drive continuous improvement across all levels of your organization.

    Lean Effective Problem Solving (EPS) & Root Cause Analysis (RCA) Trainingequips teams with practical tools to quickly identify, analyze, and solve problems at their root, driving lasting improvements and operational excellence.

    Lean Product Development (LPD) helps teams bring better products to market faster by streamlining development processes, improving collaboration and reducing rework and delays.

    Not Seeing a topic? Contact your Regional Manager to discuss our other applications or to schedule a discovery call.

    Value Stream Mapping
    Value Stream Analysis

    The purpose of value stream analysis is to visualize, analyze and improve the end-to-end steps required to deliver a product or service so that an organization can eliminate waste and maximize customer value.

    This goal can be accomplished in many different ways but the most common is utilizing the value stream mapping tool. When used effectively, this analysis and toolset can help organizations and individuals to better understand material and information flows as well as current processes, identifying opportunities for improvement.

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    Value Stream Mapping

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    Using Value Stream Mapping, teams can streamline processes, reduce lead times and lower operating costs, driving measurable operational improvements.

    Participants will:

  • Identify the current state of flow, understanding value and wastes within your processes
  • Analyze all products from a system-wide perspective
  • Map material and information flows across the value stream
  • Design a blueprint for lean transformation with a future-state map
  • Prioritize activities to achieve the future-state goals
  • Topics covered:

  • Introduction to the Value Stream Mapping methodology
  • Mapping material and information flows across all manufacturing steps, including finished product delivery
  • Identifying opportunities to streamline processes, reduce lead times and lower operating costs
  • Duration:

    8 Hours | 1 Day

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Anyone responsible for initiating or leading lean, including CEOs, general managers, production managers, controllers, engineers and materials managers. Suggested follow-up: an in-plant value stream analysis.

    Contact your Regional Manager to schedule.

    Lean Facility Flow & Layout

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    Lean Facility Flow and Layout helps organizations design smarter, more efficient workspaces that improve the movement of people, materials and information throughout their operations. By evaluating current workflows, identifying bottlenecks, unnecessary movement, space constraints and other sources of waste, organizations can develop facility layouts that support smoother processes and more productive work environments.

    Our experts use lean principles and data-driven analysis to help manufacturers optimize equipment placement, workstations, material flow, storage and overall use of available space. Whether planning a new facility, expanding an existing operation, or improving the efficiency of a current layout, we help organizations create practical solutions that can reduce waste, improve safety and ergonomics, increase throughput and support long-term operational growth.

    Duration:

    8 Hours | 1 Day

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Anyone responsible for initiating or leading lean, including CEOs, general managers, production managers, controllers, engineers and materials managers. Suggested follow-up: an in-plant value stream analysis.

    Contact your Regional Manager to schedule.

    5S
    5S

    5S Training teaches participants how to organize and standardize the workplace to improve efficiency, safety and quality. Our 5S training programs provide the foundational tools necessary to optimize workplace efficiency and foster a culture of continuous improvement.

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    5S training includes hands-on learning; participants will learn to sort, set in order, shine, standardize and sustain work areas, creating a clean and organized environment. The course equips teams with practical skills to reduce waste, streamline processes and maintain consistent, high-performing operations.

    Participants will:

  • Learn the 5S system
    • SORT through what you have and remove what you don’t need
    • SET IN ORDER what remains, making space visual and self-explanatory
    • SHINE up tools, equipment and work spaces, keeping them spotless
    • STANDARDIZE and follow work rules scrupulously
    • SUSTAIN by maintaining the discipline in 5S
  • Understand how to create a visual management system in your workplace
  • Topics covered:

  • Creating a stable, consistent, predictable workplace
  • Addressing and implementing each of the 5S, in chronological order
  • Integrating safety into each of the 5S’s
  • Implementing a visual management system that allows one to differentiate normal conditions from abnormal almost immediately
  • Importance of sustainment in 5S efforts
  • Duration:

    7-8 Hours | 1 Day (training class)
    21-24 Hours – 3 Days (implementation kaizen)

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Anyone with a desire to improve a work area or office area with continuous improvement tools to improve flow and create a visual work system  including office managers, supervisors, lead operators, industrial/manufacturing engineers and quality managers.

    Contact your Regional Manager to schedule.

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    Standard Work

    Standard Work Training teaches participants how to develop standard work, which is essential to improving processes in a Lean environment. Our 5S training programs provide the foundational tools necessary to create, document and implement standardized processes in the participants’ workplaces.

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    Standard Work training includes hands-on learning; participants will learn to develop standard work (the least wastful way of doing a task), creating a stable environment ready for effective operations and process improvement. The course equips teams with practical skills to implement standardized work in their workplaces.

    Participants will:

  • Learn the importance of standard work and how to develop it, especially with a focus on three key elements: takt time, work sequence and standard work-in-progress.
  • Topics covered:

  • Takt time (vs. cycle time)
  • Work sequence
  • Work-in-progress
  • Time observation sheet
  • Standard work combination sheet
  • Standard work layout
  • Cycle time bar chart
  • Work instruction sheet
  • How to develop a process that eliminates walking, reduces waste, improves quality and increases productivity
  • Duration:

    7-8 Hours | 1 Day (training class)
    21-24 Hours – 3 Days (implementation kaizen)

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Anyone with a desire to improve a work area or office area with continuous improvement tools focused on process standardization and documentation,  including office managers, supervisors, lead operators, industrial/manufacturing engineers and quality managers.

    Contact your Regional Manager to schedule.

    Total Productive Maintenance (TPM)
    Total Productive Maintenance (TPM)

    Total Productive Maintenance (TPM) teaches participants how to maximize equipment effectiveness and reliability through proactive maintenance, employee engagement and continuous improvement. The course covers techniques to prevent breakdowns, reduce downtime and improve overall equipment efficiency (OEE), while fostering a culture of ownership and teamwork across all levels of the organization.

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    Total Productive Maintenance covers techniques to prevent breakdowns, reduce downtime, and improve overall equipment efficiency (OEE), while fostering a culture of ownership and teamwork across all levels of the organization.

    Participants will:

  • Identify and prevent equipment failures to maximize uptime
  • Implement proactive maintenance strategies to improve reliability
  • Apply techniques to measure and improve Overall Equipment Effectiveness (OEE)
  • Engage operators and teams in maintaining equipment and sustaining improvements
  • Foster a culture of continuous improvement and ownership across the organization
  • Topics covered:

  • Principles and objectives of Total Productive Maintenance
  • Techniques for proactive and preventive maintenance
  • Measuring and improving Overall Equipment Effectiveness (OEE)
  • Operator involvement and teamwork in maintaining equipment
  • Sustaining continuous improvement and a culture of equipment ownership
  • Duration:

    21-24 Hours | 3 Days

    Format:

    Customized on-site workshop, in-person instruction

    Recommended For:

    Equipment operators, maintenance personnel, supervisors, team leaders, and plant managers responsible for equipment reliability and operational efficiency. It is also recommended for continuous improvement professionals and Lean practitioners seeking to implement proactive maintenance strategies, improve overall equipment effectiveness (OEE) and foster a culture of ownership and collaboration across the organization.

    Contact your Regional Manager to schedule.

    Setup Reduction (SMED)
    Setup Reduction (SMED)

    SMED (Single Minute Exchange of Dies), or Changeover Reduction, focuses on reducing the time and impact of key elements in the changeover process, including preparation; after-process adjustment; checking, storing and moving materials, parts and tools; removing and mounting parts and tools; machine measurements, settings and calibrations; trial runs and adjustments.

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    SMED (Single-Minute Exchange of Dies) training teaches participants how to reduce equipment setup and changeover times, increase productivity, and standardize processes for faster, more efficient operations.

    Participants will:

  • Analyze current setup and changeover processes to identify inefficiencies
  • Apply techniques to reduce internal and external setup times
  • Standardize quick-change procedures for consistency and reliability
  • Implement improvements to increase equipment uptime and productivity
  • Sustain setup time reductions through continuous improvement practices
  • Topics covered:

  • Principles and objectives of SMED (Single-Minute Exchange of Dies)
  • Analyzing current setup processes to identify inefficiencies
  • Techniques to reduce internal and external setup times
  • Standardizing quick-change procedures to improve consistency
  • Measuring and sustaining setup time improvements for continuous efficiency
  • Duration:

    21-24 Hours | 3 Days

    Format:

    Customized on-site workshop, in-person instruction

    Recommended For:

    Machine operators, setup technicians, production supervisors, maintenance personnel, and manufacturing engineers responsible for equipment changeovers and operational efficiency. It is also recommended for continuous improvement professionals and Lean practitioners who want to reduce downtime, increase machine productivity and implement faster, standardized changeover processes across their organization.

    Contact your Regional Manager to schedule.

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    Lean Culture & Workforce

    Lean Culture is found in an environment where everyone’s main focus is on two key principles: continuous improvement and respect for all individuals. It is evidenced by ongoing process improvement and the elimination of waste in a systematic way, with the end goal of delivering the highest possible value to the customer (internal and/or external).

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    Standard Work For Lean Leaders

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    Taiichi Ohno, one of the founders of the Toyota Production System, once said, “The greatest waste of all is the waste that we don’t see.” It is impossible to lead in a continuously improving environment without being able to identify waste that keeps our operation or service from performing at a high level.

    Participants will:

  • Understand how to challenge staff (especially front-line leaders) to identify waste that is keeping their operation from performing more effectively.
  • Gain the ability to understand the purpose of a leader in a Lean environment
  • Learn the importance of performing confirmation checks in your work environment to confirm the status of your material, information and people flow and identify opportunities to improve
  • Teach and coach others in your organization to see waste
  • Duration:

    7-8 Hours | 1 Day

    Format:

    Customized on-site Training

    Recommended For:

    Managers and front-line leaders who want to build a continuous improvement culture that is practiced daily, not event-based.

    Contact your Regional Manager to schedule.

    Toyota Kata

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    By practicing Toyota Kata routines, teams become better equipped to navigate ambiguity, achieve challenging goals, and strengthen organizational capability. The approach also builds bench strength through appreciative inquiry and a structured coaching model, supporting sustainable improvement across the organization.

    Participants will:

  • Leverage the scientific thinking model
  • Utilize both the Improvement Kata and Coaching Kata
  • Apply techniques of deliberate practice
  • Develop and operationalize improvement Kata patterns
  • Create a deliberate culture for learners and coaches
  • Topics covered:

  • Identify and drive improvement of processes
  • Develop the fundamental skills of working like a scientist
  • Iterate or experiment his or her way toward a desired goal
  • Successfully deal with uncertainty and challenges
  • Duration:

    Variable: Ranging from 1-6 days
    1 Day Overview, 2 Days On-site Training and 3 Days of Project Implementation and Coaching

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Professionals—such as team leaders, supervisors, and managers—who have completed Yellow Belt training or have process improvement experience and are ready to lead or support cross-functional projects.

    Contact your Regional Manager to schedule.

    Managing for Daily Improvement

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    Managing for Daily Improvement (MDI) teaches organizations how to drive performance and problem-solving at the front line through visual management and daily engagement with key performance indicators (KPIs).

    Managing for Daily Improvement makes problems visible and engages the entire team in rapid, data-driven problem solving. By shifting from a traditional top-down management approach to a bottom-up system of continuous improvement, MDI fosters a culture of daily performance management and drives operational excellence.

    Participants will:

  • Learn how to create, implement and lead daily huddles
  • Focus improvement on key performance indicators
  • Identify small barriers and challenges
  • Evaluate the obstacle(s)
  • Correct the problem quickly
  • Standardize the process
  • Measure the results in real time
  • Topics covered:

  • Align the strategic plan (Hoshin Kanri) with daily tasks and performance metrics
  • Apply scientific thinking to advance continuous improvement efforts
  • Explain the principles and key concepts of Managing for Daily Improvement (MDI)
  • Identify the essential elements of a daily huddle
  • Define participant roles and responsibilities in daily huddles
  • Provide effective coaching during daily huddles
  • Apply leadership practices in daily huddles, including the Socratic Method
  • Duration:

    8 Hours | 1 Day

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Supervisors, team leaders, managers, and operational leaders who are responsible for driving daily performance, engaging frontline teams, and fostering a culture of continuous improvement. It is also recommended for Lean practitioners and continuous improvement professionals who want to implement visual management, problem-solving routines and data-driven decision-making at the operational level.

    Contact your Regional Manager to schedule.

    Hoshin Kanri

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    Hoshin Kanri teaches organizations how to align strategy, goals, and daily operations to drive meaningful, measurable results. Hoshin Kanri methodology uses a structured planning and deployment cycle to set goals, establish action plans, and define metrics that ensure progress at every level.

    Hoshin Kanri eliminates waste caused by misalignment and poor communication, creating a unified organization in which every employee works toward the same priorities. Participants learn to integrate strategic planning with continuous improvement tools, conduct SWOT analyses, refine mission and vision and implement rigorous reviews to maintain focus, transparency and consistent progress toward organizational “true north.” 

    Participants will:

  • Shorten the communication cycles
  • Create a more fluid way of information sharing
  • Sustain a long-term focus while allowing for easy adjustments
  • Determine goals
  • Create measurement methods
  • Eliminate waste
  • Topics covered:

  • Principles and key concepts of Hoshin Kanri
  • Core processes, tools and essential elements of Hoshin Kanri
  • Step-by-step approach to planning, implementation and review for managing organizational change
  • Practical application of Hoshin Kanri tools, processes and strategic alignment
  • Duration:

    Overview: 7 Hours | 1 Day
    Implementation:14-16 Hours | 2 Days

    Format:

    Customized on-site, in-person instruction

    Coaching:

    Customized implementation coaching services are available after course completion.

    Recommended For:

    Executives, senior leaders, and managers responsible for setting organizational strategy and driving alignment across teams. It is also recommended for continuous improvement professionals, operational leaders and project managers who need to link corporate goals with day-to-day operations, ensure consistent progress toward strategic objectives, and foster a culture of accountability and focus throughout the organization.

    Contact your Regional Manager to schedule.

    Lean HR

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    Lean HR can assist human resources in identifying value, mapping the value stream, creating flow, establishing pull and seeking perfection.

    Lean for Human Resources is a fundamental change in how you and the people in your organization think and approach problems. Lean is a common set of beliefs and principles that focus on what is of value in every facet of your HR Department.

    When rigorously applied, Lean for Human Resources can have positive impacts on productivity, cost, quality and delivery of services.

    Participants will:

  • Do more with fewer people
  • Do the right things, the right way, with the right people
  • Reduce time to hire
  • Meet leave of absence requests in a timely and compliant fashion
  • Topics covered:

  • Basic disciplines including Standardized Work
  • 5S
  • Error Proofing
  • Kanban
  • Visual Control
  • Duration:

    7–8 Hours | 1 Day

    Format:

    Customized on-site, in-person instruction or Virtual instructor-led training (VILT)

    Coaching:

    Customized implementation coaching services are available after course completion.

    Recommended For:

    Professionals in the human resources field.

    Contact your Regional Manager to schedule.

    Lean HR

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    Lean HR can assist human resources in identifying value, mapping the value stream, creating flow, establishing pull and seeking perfection.

    Lean for Human Resources is a fundamental change in how you and the people in your organization think and approach problems. Lean is a common set of beliefs and principles that focus on what is of value in every facet of your HR Department.

    When rigorously applied, Lean for Human Resources can have positive impacts on productivity, cost, quality and delivery of services.

    Participants will:

  • Do more with fewer people
  • Do the right things, the right way, with the right people
  • Reduce time to hire
  • Meet leave of absence requests in a timely and compliant fashion
  • Topics covered:

  • Basic disciplines including Standardized Work
  • 5S
  • Error Proofing
  • Kanban
  • Visual Control
  • Duration:

    7–8 Hours | 1 Day

    Format:

    Customized on-site, in-person instruction or Virtual instructor-led training (VILT)

    Coaching:

    Customized implementation coaching services are available after course completion.

    Recommended For:

    Professionals in the human resources field.

    Contact your Regional Manager to schedule.

    Toyota Kata and The PIT Experience
    Toyota Kata PIT Experience Workshop

    Toyota Kata is a managerial approach that fosters continuous improvement through scientific thinking. It develops a mindset that enhances problem-solving effectiveness and builds a culture that maximizes the impact of traditional Lean tools.

    The Toyota Kata Overview PIT Experience, taught at the Performance Instruction &
    The Training (PIT) facility, deep in NASCAR country, challenges participants to approach problem-solving in an entertaining, easy-to-understand way. This is provided through the pit stop experience, a team-based event that is analyzed to evaluate performance, identify learnings and make modifications for continuous improvement.

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    Toyota Kata PIT Experience workshop leverages a combination of classroom presentation, discussion and actual pit crew activities to drive home the concepts of continuous improvement, efficiency, preparation and teambuilding, while addressing such topics as communication, role responsibility, creative thinking and work performance.

    Participants will:

  • Look at problem-solving in an entertaining format as a pit crew team member
  • Apply Lean principles, communication strategies and teamwork
  • Develop and operationalize improvement Kata patterns
  • Evaluate performance, identify learnings and make modifications for continuous improvement
  • Topics covered:

  • Identify and drive improvement of processes
  • Develop the fundamental skills of working like a scientist
  • Iterate or experiment his or her way toward a desired goal
  • Successfully deal with uncertainty and challenges
  • Duration:

    8 Hours | 1 Day On-site at the PIT facilities

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Managers, supervisors, team leaders and emerging leaders who are responsible for driving continuous improvement within their organizations. It is also well-suited for Lean practitioners, process improvement professionals and anyone looking to develop the coaching and problem-solving mindset needed to sustain a culture of improvement.

    Contact your Regional Manager to schedule.

    Lean Six Sigma
    Lean Six Sigma Processes

    Lean Six Sigma is a disciplined, data-driven methodology designed to deliver consistent, high-quality results by identifying and eliminating the root causes of defects, aiming to achieve near-zero variation and error across products and services.

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    Lean Six Sigma Yellow Belt

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    Lean Six Sigma Yellow Belt training introduces participants to the fundamentals of process improvement, equipping them with the core tools used to identify waste, reduce variation and improve quality. You will learn how to apply Lean and Six Sigma concepts, support improvement projects and contribute effectively to teams using data-driven problem solving and the DMAIC framework.

    Participants will:

  • Take part in a hands-on “Tube Factory” simulation with two rounds of instruction
  • Apply Lean Six Sigma tools in a realistic production environment and reinforce learning through guided coaching
  • Gain practical experience using a wide range of foundational LSS tools
  • Topics covered:

  • Overview of Lean Six Sigma, its business benefits and DMAIC methodology
  • Cost of Poor Quality and Voice of the Customer
  • Process mapping tools (including SIPOC and process flow) and core Lean tools (Value Analysis, 8 Wastes)
  • Problem solving and error proofing
  • Duration:

    16 Hours | 2 Days

    Format:

    Customized in-person, on-site

    Recommended For:

    Anyone in an organization who wants to learn Lean Six Sigma principles at a high level, from executive leadership to individually contributing associates.

    Contact your Regional Manager to schedule.

    Lean Six Sigma Green Belt Certification

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    Lean Six Sigma Green Belt training builds on Yellow Belt fundamentals to prepare participants to lead improvement projects that deliver measurable business results. You will gain deeper expertise in data-driven problem solving, statistical analysis and the DMAIC methodology, enabling you to identify root causes, reduce variation and drive sustainable process improvements across your organization.

    Participants will:

  • Receive a tailored Lean Six Sigma training program with customized content to meet their organization’s specific needs
  • Build an internal network of problem solvers
  • Achieve a highly engaged workforce, improved processes and measurable time and material savings
  • Topics covered:

  • Introduction to Lean Six Sigma
  • Cost of Poor Quality
  • Define: Launching the Project
  • Voice of the Customer
  • Introduction to Minitab*
  • Core Project Tools
  • Creating Graphs in Minitab*
  • Concept of Process
  • Core Lean Principles
  • Intro to Measure
  • FMEA
  • Basic Statistics
  • Measurement Systems Analysis
  • Process Capability
  • Introduction to Analyze
  • Using Graphs to Determine Root Causes
  • Inferential Statistics
  • T-Tests on the Mean
  • Correlation
  • Linear Regression
  • Introduction to Improve
  • Lean Improvement Tools
  • Design of Experiments
  • Error Proofing and Innovative Problem Solving
  • Pilots and Full Scale Implementation
  • Introduction to Control
  • Control Charts
  • Implementing Solutions
  • Duration:

    12 days (Total)
    8 instructional days: 7 days (didactic) classroom training + 1 test day (8th day)
    3 tollgate coaching days (DMAIC)
    1 project presentation/certification day

    Format:

    Customized in-person, on-site. Catapult Lab is used for onsite experiential learning and LSS tool application.

    *Minitab software is utilized during this course. Participants are provided a copy of this software for the duration of their class experience.

    Day 1 – Define
    Day 2 – Define/Measure
    Day 3 – Measure
    Day 4 – Analyze
    Day 5 – Analyze/Improve
    Day 6 – Improve
    Day 7 – Control
    Day 8 – Exam
    Day 9 – Toll Gate Check In
    Day 10 – Toll Gate Check In
    Day 11 – Toll Gate Check In
    Day 12 – Final Project Report Out and Presentations

    Recommended For:

    Professionals—such as team leaders, supervisors, and managers—who have completed Yellow Belt training or have process improvement experience and are ready to lead or support cross-functional projects.

    Contact your Regional Manager to schedule.

    Lean Six Sigma Black Belt Certification

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    Lean Six Sigma Black Belt certification equips experienced practitioners to lead complex process improvement projects, mentor Green Belts and drive measurable business results.

    Black Belt training is offered in two formats:

  • Option 1: On-site training for certified Green Belts to advance to Black Belt, including two additional weeks of class, a certification project and an assessment.
  • Option 2: On-site training for participants without prior Green Belt certification, delivered over four days per week across three months, combining Green and Black Belt content with DMAIC project work.
  • IES provides dedicated coaching to ensure successful project completion and implementation of lasting process improvements.

    Participants will:

  • Gain advanced Lean methodologies, statistical analysis skills and expertise in the DMAIC framework.
  • Topics covered:

  • Project Management & DFSS: including Design FMEA and Nested Gage R&R
  • Data Analysis & Hypothesis Testing: capability analysis, ANOVA, chi-square, nonparametric tests, regression, t-tests and sample size determination
  • Design of Experiments (DOE): fractional factorial, blocking and response surface designs
  • Lean & Continuous Improvement Tools: TPM, TRIZ, 3P, SPC for non-normal data, Toyota Kata and Standard Work for Leaders
  • Duration:

    8-15 days
    Variable: Ranging from 8 days with Green Belt certification (IES or COT) to or up to 15 days without previous Lean Six Sigma certification (+2)

    Format:

    Customized in-person

    Recommended For:

    Experienced professionals who lead complex improvement projects, mentor Green Belts and drive organizational process excellence.

    Contact your Regional Manager to schedule.

    Training Within Industry (TWI)
    Training Within Industry (TWI)

    Training Within Industry (TWI) is a proven, hands-on training methodology that strengthens standard work, improves performance and builds consistent leadership practices. By establishing this foundation, TWI helps organizations achieve operational excellence and drive meaningful, lasting cultural transformation.

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    Training Within Industry

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    Training Within Industry (TWI) overview equips supervisors and team leaders with the practical skills needed to lead people, improve processes, and build consistency on the job. TWI combines proven methods with hands-on, real-world application to help organizations strengthen performance, develop frontline leadership and create a culture of operational excellence.

    Participants will:

  • Plan and lead a TWI implementation with clear roles, goals and metrics
  • Design and launch a pilot program. Apply Job Instruction, Job Relations, and Job Methods to train people, improve processes and strengthen teamwork
  • Create and sustain standard work
  • Measure results, audit performance and drive continuous improvement
  • Topics covered:

  • Training Within Industry Overview
  • Training Within Industry Job Instructions (TWI-JI)
  • Training Within Industry Job Relations (TWI-JR)
  • Training Within Industry Job Methods (TWI-JM)
  • Duration:

    7-8 Hours | 1 Day

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Supervisors, team leaders and anyone who directs the work of others.

    Contact your Regional Manager to schedule.

    TWI – Job Instructions

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    Training Within Industry – Job Instructions teaches supervisors and team leaders how to quickly train employees to perform work correctly, safely, and consistently. The course provides a standardized methodology that delivers immediate results through faster, more effective skill transfer. Over the long term, it builds trust, strengthens teamwork and fosters a culture of open communication and continuous improvement.

    Participants will:

  • Learn a methodology for standardization to effectively train employees to work safely, correctly and consistently
  • Create clear job breakdowns
  • Reduce errors and training time
  • Build trust between instructors and learners
  • Improve teamwork and communication
  • Topics covered:

  • TWI Job Instruction principles and training methodology
  • Creating and using Job Breakdown Sheets to standardize work
  • Delivering clear, consistent instruction and verifying skill mastery
  • Coaching and reinforcing correct work practices
  • Duration:

    3 days total (see below)
    10 hours of instruction (didactic) + 10-14 coaching reps (hands on practice)

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Supervisors, team leaders and anyone who directs the work of others.

    Contact your Regional Manager to schedule.

    TWI – Job Relations

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    Training Within Industry – Job Relations teaches supervisors and team leaders how to build positive employee relationships, increase cooperation, and boost motivation. The course provides practical strategies and a simple 4-step approach to effectively address workplace issues. Over time, it fosters respect, teamwork, and a more focused, high-performing work environment.

    Participants will:

  • Build positive relationships with employees and team members
  • Increase cooperation and motivation across their teams
  • Address workplace issues using a structured 4-step approach
  • Model fair, respectful behavior to strengthen team dynamics
  • Reduce distractions and create a more focused, high-performing environment
  • Topics covered:

  • Principles of effective employee relations and team dynamics
  • Techniques for building cooperation and motivation
  • The 4-step approach to handling workplace issues
  • Modeling respectful and fair behavior to foster trust
  • Strategies for sustaining a positive, high-performing work environment
  • Duration:

    2 days total (see below)
    10 hours of instruction + 2 coaching reps (6 hrs)

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Supervisors, team leaders and anyone who directs the work of others.

    Contact your Regional Manager to schedule.

    TWI – Job Methods

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    Training Within Industry – Job Methods teaches supervisors and team leaders how to analyze and improve work processes to increase efficiency, reduce waste, and enhance quality. The course provides practical techniques for evaluating current methods, identifying opportunities for improvement and implementing changes to optimize performance while engaging employees in continuous improvement.

    Participants will:

  • Analyze existing work processes to identify inefficiencies
  • Develop improved methods to increase productivity and quality
  • Implement changes that reduce waste and streamline operations
  • Engage employees in problem-solving and continuous improvement
  • Standardize and sustain better work practices across teams
  • Topics covered:

  • Analyzing current work processes to identify improvements
  • Developing and testing more efficient methods
  • Implementing changes to reduce waste and enhance quality
  • Standardizing and sustaining improved work practices
  • Engaging employees in problem-solving and continuous improvement
  • Duration:

    3 days total (see below)
    10 hours of instruction (didactic) + 10-14 coaching reps (hands on practice)

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Supervisors, team leaders and anyone who directs the work of others.

    Contact your Regional Manager to schedule.

    Cost Estimating
    Cost Estimating

    The Financial-Based Decision Making and Cost Estimating program equips manufacturers with the skills to make data-driven, cost-conscious decisions that maximize operational efficiency and profitability.

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    Financial-Based Decision Making and Cost Estimating  to apply cost estimation, financial analysis and performance metrics to prioritize resources and select the most valuable production strategies.

    Participants will:

  • Apply cost estimation methods and understand different types of costing, including value stream costing
  • Analyze financial metrics such as ROI, ROS and performance indicators to guide decision-making
  • Compare pricing and production options to determine the most cost-effective strategies
  • Evaluate the impact of quality, including Cost of Poor Quality (CPQ), on overall profitability
  • Use break-even analysis, payback periods, and cost management principles to optimize resource allocation
  • Topics covered:

  • Costing methods and levels, including value stream costing and cost accounting vs. cost estimation
  • Financial analysis and performance metrics, such as ROI and ROS
  • Pricing strategies, cost comparison frameworks and resource allocation
  • Cost of Poor Quality (CPQ) and its impact on profitability
  • Break-even analysis, payback periods, and decision-making tools for production planning
  • Duration:

    7-8 Hours | 1 Day

    Format:

    Customized on-site, in-person instruction

    Recommended For:

    Manufacturing leaders, plant managers, operations and production managers, financial professionals and anyone responsible for budgeting, cost control or strategic decision-making in production environments. It is especially valuable for those seeking to make data-driven decisions that improve efficiency and profitability.

    Contact your Regional Manager to schedule.

    Ergonomic Assessment
    Ergonomics Assessment

    Our Ergonomic Assessment helps organizations identify workplace risk factors to improve employee comfort, safety and productivity. Ergonomic training and consulting services help design a healthier, happier workplace, reducing worker compensation claims, absenteeism and employee turnover.

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    Ergonomic Assessment

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    An ergonomic assessment helps organizations create safer, healthier and more efficient work environments by identifying workplace conditions that may contribute to employee discomfort, fatigue, or musculoskeletal injuries. Industry Extension Services professionals work alongside your team to evaluate job tasks, workstations, equipment and employee movements to identify ergonomic risks and opportunities for improvement.

    The assessment examines factors such as repetitive motions, lifting and material handling practices, workstation design, employee posture, tool selection, force requirements, and workflow efficiency. Our experts provide practical recommendations that reduce physical strain, improve employee comfort, and support a safer, more productive workplace.

    At the conclusion of the assessment, your organization will receive prioritized, actionable recommendations that help minimize injury risks, reduce workers’ compensation costs, improve employee well-being and enhance operational performance. The goal is to create a work environment that supports both employee health and business productivity, resulting in a stronger, more engaged workforce and sustainable long-term success.

    Benefits of an ergonomic assessment:

  • Reduces the risk of musculoskeletal injuries and repetitive-strain disorders
  • Improves employee comfort, focus and overall job performance.
  • Decreases lost time, workers’ compensation claims, and associated costs
  • Enhances compliance with safety and health best practices
  • Supports a healthier, more engaged and more productive workforce
  • Duration:

    7-8 Hours | 1 Day

    Format:

    On-site, in-person assessment

    Recommended For:

    Any organization with employees who perform repetitive tasks, computer-based work, material handling or physically demanding jobs—including manufacturing plants, warehouses, healthcare facilities and business offices.

    Contact your Regional Manager to schedule.

    Ergonomic Training Programs

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    Ergonomics training programs focus on minimizing and eliminating the causes of workplace injuries. We offer several different workshops:

  • Employee Awareness Training
    Duration: 0.5-1 hour
  • Leadership Awareness Training
    Duration: 2 hours
  • Ergonomics Team Training
    Duration: 3 days
  • Ergonomics for Engineers
    Duration: 2 to 3 days
  • ErgoTASK
    Duration: 1-3 days Kaizen event
  • Stressor Stroll: Eyes on Ergonomics
    Duration: 4 or 8 hours
  • Format:

    Customized on-site, in-person instruction or Virtual Instructor-led Training (VILT)

    Recommended For:

    Any organization with employees who perform repetitive tasks, computer-based work, material handling or physically demanding jobs—including manufacturing plants, warehouses, healthcare facilities and business offices.

    Contact your Regional Manager to schedule.

    Ergonomic Consulting

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    Ergonomic consulting provides expert guidance to reduce workplace risk factors, improve workstation and job design, prevent injuries, increase productivity and create a safer, more comfortable work environment.

    Consulting services:

  • Workstation Design
  • Hand Tool Design and Selection
  • Manual Material Handling (MMH)
  • Strength Limits (grip, torque)
  • Manufacturability, Usability, Serviceability
  • Cart and Caster Design
  • Environmental
  • Duration:

    Varies

    Format:

    Varies

    Recommended For:

    Any organization with employees who perform repetitive tasks, computer-based work, material handling or physically demanding jobs—including manufacturing plants, warehouses, healthcare facilities and business offices.

    Contact your Regional Manager to schedule.

    Industrial Engineering
    Process Optimization Services

    Our Industrial Engineering services leverage advanced tools and expert analysis to improve efficiency, reduce risk and drive smarter business decisions.

    3D Digital Twin Scans
    Facility Layout
    Process Simulation
    Work Measurement: Time and Motion Studies

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