Course Overview

Lean Supply Chain & Process Optimization

 Start Date: January 10, 2026
Duration: 20 Hours
Mode: Hybrid
Class Size: 40 participants
Course Equivalent: 1 Credit Hour
Course Fee: BDT 3,000

Course Description

This course provides a practical, hands-on understanding of Lean principles and their application across end-to-end supply chain operations. Learners will explore waste elimination techniques, value stream mapping, cycle time reduction, Kaizen-based continuous improvement, and real-world optimization tools used in warehousing, logistics, production, and procurement. The program emphasizes practical exercises and industry case studies to prepare participants for operational excellence roles.

Syllabus 

Module 1: Introduction to Lean Thinking (2 Hours)

Topics:

• What is Lean?
  
  
• Lean vs Traditional Supply Chain
  
  
• 5 Lean Principles
  
  
• Define value
  
  
• Map value stream
  
  
• Create flow
  
  
• Establish pull
  
  
• Pursue perfection
  
  
• Lean mindset & continuous improvement culture
  
  

Activity:

• Short simulation: “Why Lean matters in supply chain"
  
  

Module 2: The Seven Wastes (Muda) in Supply Chain (3 Hours)

Topics:

• 7 Wastes (TIMWOOD): Transportation, Inventory, Motion, Waiting, Overproduction, Over-processing, Defects
  
  
• Additional waste: Unused talent
  
  
• Waste identification in: Warehousing, Procurement, Production, Transportation, Order processing
  
  

Practical:

• Waste identification exercise using a real process flow
  
  

Module 3: Lean Tools for Supply Chain Optimization (3 Hours)

Topics:

• Core Lean Tools: 5S, Standard Work, Kanban, Pull Systems, JIT, Visual Management, Poka-Yoke, Root Cause Analysis
  
  
• Application Areas: Warehouse layout optimization, Inventory reduction, Order fulfillment improvement
  
  

Practical:

• Create a Kanban card system for a hypothetical warehouse
  
  

Module 4: Value Stream Mapping (VSM) Fundamentals (3 Hours)

Topics:

• What is VSM?
  
  
• Current State vs Future State Maps
  
  
• Value-added vs non-value-added analysis
  
  
• VSM symbols & conventions
  
  
• Mapping material & information flow
  
  

Practical:

• Create a Current State VSM
  
  
• Identify bottlenecks and wastes
  
  

Module 5: Cycle Time, Lead Time & Process Analysis (2 Hours)

Topics:

• Cycle time vs lead time vs takt time
  
  
• Bottleneck analysis
  
  
• Demand vs capacity alignment
  
  
• Push vs pull systems
  
  
• Inventory impact on cycle time
  
  

Practical (Excel):

• Calculate cycle & takt time
  
  
• Identify bottlenecks in a process flow
  
  

Module 6: Kaizen in Supply Chain (3 Hours)

Topics:

• What is Kaizen?
  
  
• Kaizen vs Kaikaku
  
  
• Kaizen event structure (problem → root cause → improvement → implementation → monitoring)
  
  
• Daily Kaizen
  
  
• Kaizen in: Inventory, Transportation, Warehouse operations, Administrative processes
  
  

Practical:

• Conduct a mini Kaizen event for a warehouse receiving process
  
  

Module 7: Process Optimization & Performance Measurement (2 Hours)

Topics:

• Lean KPIs: OEE (conceptual), PCE, Inventory days, OCT
  
  
• PDCA cycle
  
  
• Improvement roadmaps
  
  
• Risk identification & mitigation
  
  

Practical:

• Build a PCE score
  
  
• Root cause analysis session
  
  

Module 8: Lean Supply Chain Case Studies (2 Hours)

Topics:

• Toyota Production System
  
  
• Amazon Lean Warehousing
  
  
• Dell Build-to-Order Model
  
  
• Unilever Lean Distribution
  
  
• Local case studies (RMG, FMCG, pharma)
  
  

Activity:

• Group presentation: “Design a Lean Future State for a Bangladesh industry supply chain”
  
  

Assessment & Certification Requirements

Assignments:

• Waste identification report
  
  
• VSM (Current + Future State)
  
  
• Kaizen improvement proposal
  
  

Final Assessment:

• MCQ + Lean optimization case study
  

Career Pathway

• Supply Chain Analyst (Lean-focused)
  
  
• Process Improvement Officer
  
  
• Lean Supply Chain Coordinator
  
  
• Warehouse Optimization Specialist
  
  
• Logistics Continuous Improvement Executive
  
  
• Industrial Engineer (Lean Operations)
  
  
• Operations Excellence Specialist
  
  
• Kaizen Facilitator
  
  
• Production & Planning Executive (Lean-enabled)