Lean Operational Excellence with AI
Operational excellence requires organizations to continuously reduce waste, improve processes, solve problems, and deliver greater value to customers. This practical course provides a foundation in Lean and Six Sigma principles while introducing AI, data analytics, and intelligent automation as modern tools for process improvement. Participants will learn to identify waste, map processes, analyze root causes, use operational data, and develop sustainable improvements. The course also explores how AI can support process analysis, problem-solving, SOP development, workflow automation, and operational decision-making. Through practical exercises and a capstone activity, participants will apply Lean, data-driven, AI, and automation techniques to a real business process and develop an AI-supported improvement plan focused on reducing waste, improving efficiency, and sustaining operational excellence.
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About this course
Operational excellence requires organizations to continuously reduce waste, improve processes, solve problems, and deliver greater value to customers. This practical course provides a foundation in Lean and Six Sigma principles while introducing AI, data analytics, and intelligent automation as modern tools for process improvement. Participants will learn to identify waste, map processes, analyze root causes, use operational data, and develop sustainable improvements. The course also explores how AI can support process analysis, problem-solving, SOP development, workflow automation, and operational decision-making. Through practical exercises and a capstone activity, participants will apply Lean, data-driven, AI, and automation techniques to a real business process and develop an AI-supported improvement plan focused on reducing waste, improving efficiency, and sustaining operational excellence.
What you'll learn
- Understand core Lean and continuous improvement principles
- Identify waste and improvement opportunities within business processes
- Map processes and identify bottlenecks, delays, and inefficiencies
- Apply root-cause analysis and problem-solving techniques
- Use operational data and KPIs to support improvement decisions
- Apply AI to analyze processes, identify patterns, and generate improvement ideas
- Improve SOPs and process documentation using AI
- Identify suitable opportunities for automation and AI-enabled workflows
- Apply human oversight and governance when using AI for operational improvement
- Develop sustainable improvement practices through standard work and KPI monitoring
- Create an AI-supported improvement plan for a real business process
Course Contents
Module One: Lean Fundamentals
- Lean principles
- Customer value
- Value vs. waste
- Process thinking
- Continuous improvement
Module Two: Identifying Waste & Improvement Opportunities
- The 8 Wastes
- Identifying waste in real processes
- Value-added vs. non-value-added activities
- Prioritizing improvement opportunities
Module Three: Process Mapping & Flow
- SIPOC
- Value Stream Mapping
- Process flowcharts
- Identifying bottlenecks
- Cycle time and lead time
Module Four: Root Cause Analysis & Problem Solving
- Problem statements
- 5 Whys
- Fishbone/Ishikawa
- Pareto analysis
- Corrective actions
- AI-assisted root-cause exploration
Module Five: Lean Six Sigma & Data-Driven Improvement
- DMAIC
- Operational KPIs
- OEE
- Throughput
- Defect rate
- Downtime
- First-pass yield
- Using data to identify improvement opportunities
Module Six: AI for Process Improvement
- Analyzing process documentation with AI
- Identifying potential bottlenecks and patterns
- Analyzing operational information
- Generating improvement ideas
- Supporting problem-solving teams
- Drafting and improving SOPs
- Human validation of AI recommendations
Module Seven: Automation & Intelligent Workflows
- Identifying automation opportunities
- Traditional automation vs. AI-enabled workflows
- AI agents and intelligent workflows
- Human-in-the-loop processes
- Automation ROI
- Selecting appropriate automation approaches
Module Eight: Sustaining Operational Excellence
- Standard work
- SOPs and control plans
- KPI monitoring
- Continuous improvement culture
- Change management and employee adoption
- AI governance, safety and human oversight
Capstone: Process Improvement Exercise
- Map a real business process
- Identify waste and improvement opportunities
- Analyze process data and root causes
- Develop improvement actions
- Identify AI and automation opportunities
- Create an AI-supported process improvement plan
Who Should Attend
- Operations Managers and Supervisors
- Process Improvement and Continuous Improvement Professionals
- Lean and Six Sigma Practitioners
- Quality Assurance and Quality Management Professionals
- Manufacturing and Production Professionals
- Supply Chain and Logistics Professionals
- Healthcare Operations Professionals
- Project and Program Managers
- Business and Process Analysts
- Engineering and Technical Professionals
- Operational Excellence and Transformation Teams
- Team Leaders responsible for process improvement
- Professionals involved in automation and workflow improvement
- Managers seeking to apply AI to operational efficiency and continuous improvement
Prerequisites
None
Course Materials
Attendees will receive a course manual with presentation slides, reference materials, practical exercises, and capstone activity resources.
Technical Requirements
- Internet access for AI tools, operational data exercises, and downloading course materials
- Supported Devices: Laptop, Tablet, Smartphone
- Access to commonly used AI tools and web-based productivity applications
Live Course Price
USD 799
Duration
1 Days
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