Kaizen Facilitator Certification Training

Learn to Lead: Apply Kaizen Tools, Conduct Kaizen Workshops and Drive Change in your organisation!

Kaizen, meaning ‘continuous improvement’ in Japanese, is a philosophy and a practical methodology for achieving sustainable efficiency, quality, and productivity improvements. Through small, incremental changes driven by employees at all levels, organizations create long-lasting cultural transformation.

The focus of Lean Kaizen is to continuously reduce Business Throughput time by identifying, reducing and eliminating MUDA (Waste). The core idea is to maximize customer value while minimizing waste. We help organisations integrate Kaizen into their culture with extensive Kaizen training programs.

Our Kaizen Facilitator training programs empower managers to apply Lean Kaizen tools effectively, fostering operational excellence and continuous improvement across the organization. We transform managers into Kaizen Leaders through practical, experience-driven learning that blends interactive presentations, real-world case studies, experiential simulations and games, collaborative group work, and hands-on practice at the Gemba.

Our team has conducted over 5000 Kaizen workshops across 80+ different industries & Trainings on, 5S, Lean Manufacturing, Just-In-Time, Total Productive Maintenance (TPM), Total Quality Management, Total Flow Management (TFM), Daily Work Management, Preventive Maintenance, Internal Kaizen Expertise and Hoshin Kanri.

Equip your team with Kaizen leadership for continuous improvement

Conduct internal assessment to identify major gaps and identify key kaizen tools to be implemented
Map value streams, analyze waste, and redesign flow (TAKT, line balance, Kanban), Design TPM program to reduce equipment losses
Facilitate Kaizen workshops and daily continuous improvements (tier meetings, huddles)
Capacity to drive measurable improvements in cost, quality, delivery, and safety

Who should attend Kaizen Facilitator Certification Training

Senior Managers

Team Leaders

Supervisors

Project Managers

Trainers

Quality, Production and Maintenance staff

Cross-functional employees driving operational excellence

Anyone keen to learn practical improvement skills

Build In-House Kaizen Leaders with Kaizen Facilitator Certification Training Program

Kaizen Leader Certification Training is a 4-day training program designed to provide participants with skills and knowledge to identify and analyse problems, implement and review kaizen projects successfully through internal Kaizen workshops to facilitate daily improvements.

Day 1 – Building the Kaizen Foundation

Building Right Mindset for Kaizen

Understanding the spirit and philosophy of Kaizen: small, continuous improvements for big impact
Overcoming resistance to change through experiential games and reflection exercises
Paradigm shift: from “problem-finder” to “solution-creator”
Role of Kaizen facilitator as a change agent

Kaizen Fundamentals

Core principles: PDCA cycle, Genchi Genbutsu (Go & See), 5S, and Standardization
Differentiating value-added vs. non-value-added activities
The 7 Wastes (Muda) – identification through real-life examples and videos
Team activity: Waste Walk on the shop floor

Waste Identification with Value Stream Mapping

Mapping current processes through Value Stream Mapping (VSM)
Identifying bottlenecks, delays, and rework loops
Group exercise: Create Current State & Future State maps
Discussion: translating VSM insights into Kaizen projects

Day 2 – Tools for Process Improvement

Flow Management and Standard Work

Understanding Flow, Takt Time, Cycle Time, and Work Balance
Designing layouts for smooth material and information flow
Creating Standard Work Instructions and visual management boards
Practical session: simulate a flow improvement exercise

Creating Pull Systems

Principles of Just-In-Time and Pull systems
Kanban system design and calculation
Managing WIP, inventory levels, and stock-outs through visual controls
Case Study: From Push to Pull in a manufacturing line

Root Cause Analysis

Problem identification and prioritization using Pareto Analysis
Deep dive into Cause & Effect (Fishbone) and 5-Why Analysis
Systematic approach to conduct root cause analysis
How to facilitate a root cause session with teams
Group exercise: Solve a real case using RCA tools

Day 3 – Equipment Effectiveness & Maintenance Kaizen

TPM Overview

Introduction to Total Productive Maintenance and its link with Kaizen
Understanding the 8 Pillars of TPM and how Kaizen facilitators support them
The role of cross-functional teams in improving equipment performance

TPM Pillar Deep Dive

Focused Improvement (Kobetsu Kaizen): Understanding OEE, 16 losses, loss calculation, and loss analysis
SMED (Single Minute Exchange of Die): Steps to reduce changeover time and improve flexibility
Autonomous Maintenance Step 1: Identifying abnormalities and tagging sources of contamination
Planned Maintenance Step 1-3: Equipment ranking, time-based and condition-based maintenance

Kaizen Project Facilitation

How to select and scope Kaizen projects
Structuring 5-day Kaizen events and daily improvement meetings
Facilitator checklist and preparation guide

Day 4 - Advanced Facilitation & Capability Building

Autonomous & Planned Maintenance – Advanced Steps

Step 2 & 3 of Autonomous Maintenance: Developing countermeasures for hard-to-access and repeat abnormality areas
Standardizing Cleaning, Lubrication, Inspection, and Tightening (CLIT)
Planned Maintenance: Spare-parts management and introduction to predictive maintenance tools

Human Skill Development for Kaizen Leaders

TWI (Training Within Industry): Job Instruction, Job Methods, and Job Relations
Preparing training material and skill matrix for on-the-floor training
Coaching teams for problem-solving and sustaining Kaizen initiatives

Quality and Process Improvement Tools

Quality Maintenance (QM): Poka-Yoke (mistake proofing), defect mapping, and prevention approach
Process Mapping and Standardization: Reducing turnaround time through process flow analysis and SOP creation

Our Kaizen Facilitator Training Experience

0 + 500

Kaizen trainings conducted

0 + 5000

successful Kaizen projects

0 + 8000

participants trained

Why choose RIB as your training partner?

Experienced Trainers

Sharing of experience and case studies with practical application by Kaizen experts, worked across various industries and sectors.

Customised Training

The training program is tailored to align with organisation goals, by initial discussions with key stakeholders.

Practical Training

Practical learning through group activities, case studies, and simulation games, ensuring an engaging and hands-on experience at both classroom and shop floor of implementing Kaizen.

Train the Trainer Program

Train-the-Trainer program is led by a highly experienced trainer and Lean Kaizen expert to enable internal capacity building and empower teams for ongoing success.

On-site and Off-site training

Flexible online and off-site Kaizen training programs designed to suit the needs of the organisation.

Result-oriented Certified Projects

Participants will get certification only after the submission of defined Kaizen projects and results delivered, ensuring target outcomes are achieved for each project.

A Glimpse into Kaizen Facilitator Training

Advanced Lean Kaizen Certification Programs

Connect with our Experts!

With experience across diverse industries and challenges, we deliver unparalleled insights and solutions especially designed as per the needs. For more details, contact us today!