Lean Champion Training Program
A comprehensive corporate program to develop internal Lean Champions who drive continuous improvement, standard work, and waste reduction across manufacturing operations.
The Lean Champion Training Program is designed to cultivate internal lean leaders who will serve as change agents on the shop floor. This 6-month blended program combines classroom instruction, hands-on kaizen events, and a capstone improvement project. Participants learn to apply Lean Six Sigma tools, lead standardized work audits, and facilitate daily management huddles. Upon completion, certified Lean Champions are expected to mentor future cohorts and sustain continuous improvement momentum.
This program applies to all manufacturing departments within the organization, including production, warehouse, quality, and maintenance. All salaried and hourly team leads, supervisors, and senior operators are eligible for nomination. The program is mandatory for any employee seeking to advance into a Lean Champion or Continuous Improvement Facilitator role. Contractors and temporary staff are excluded unless explicitly sponsored by the Plant Manager.
- All Lean Champions must complete the foundational Lean Methods course (40 hours) before participating in any kaizen event.
- Each Lean Champion must lead at least one kaizen event per quarter, documented in the daily management system.
- Weekly Gemba walks are mandatory: each champion must walk their assigned area at least twice weekly and post findings on the team board.
- Standard work audits must be performed weekly using the provided digital checklist; audit scores are reviewed in the plant weekly management review.
- All training materials, audit results, and improvement projects must be uploaded to the digital SOP library within 5 business days of completion.
- Lean Champion (Trainee): Attends all training sessions, completes assignments, leads a kaizen project, and passes the final assessment. Must maintain an audit score of ≥90% to retain certification.
- Lean Coach (Mentor): Assigned to each champion; provides real-time coaching, reviews projects, and signs off on competencies. Must meet with mentee weekly.
- Plant Manager: Sponsors the program, approves candidate nominations, ensures resources (time, budget) for kaizen events, and reviews quarterly progress.
- Training Coordinator: Manages training schedules, materials, attendance tracking, and certification records. Liaises with external trainers if required.
- Continuous Improvement Director: Oversees program consistency across sites, updates curriculum, and conducts annual program effectiveness review.