Description
The Lean Champion programme is a 12-day advanced training designed for managers who want to roll out Lean as a business strategy within their organisation. The programme consists of two modules.
The first module is the 8-day Green Belt in Lean track, which introduces Lean as a business strategy, the principles behind it and a selected set of core Lean improvement tools. Special attention is given to analysing and designing value streams, both in production and office/service environments. Participants learn how to eliminate non-value-adding activities, improve flow and reduce cost, lead time and quality issues.
Techniques such as Value Stream Mapping, 5S, Kaizen, Problem Solving, Jidoka, TPM, Pull/Kanban and SMED are studied through theory, exercises and real cases. Several sessions are delivered by former Master Trainers from Toyota and other leading organisations.
The second module focuses on designing the Lean organisation. Participants explore Lean management techniques, cultural aspects and change management. Through cases and exercises, they learn how to build a lean operating system, a human resources development framework and financial,value stream driven cost models that support Lean. Real-world insights from Toyota, Mars Food and Johnson & Johnson are shared by our speakers.
The Lean Champion programme prepares leaders to guide improvement initiatives, support Lean transformation and build long-term organisational capability.
Prerequisites
No specific prior training is required.
Benefits
This programme gives managers a deep understanding of Lean as a strategy and enables them to lead and support impactful transformation initiatives across the organisation.
After completing this course, participants will be able to:
✓ Understand Lean as a strategic management system, not just a set of tools
✓ Analyse and redesign value streams in production and office/service environments
✓ Detect, analyse and solve problems using structured Lean and TPS methods
✓ Apply essential Lean tools such as 5S, Standard Work, Kaizen, Jidoka, Kanban and SMED
✓ Build operational stability and improve flow, quality and lead times
✓ Understand HRD, change management and culture-building for Lean organisations
✓ Use Value Stream Costing to link flow improvements with financial impact
✓ Lead or support major continuous improvement initiatives within their department
✓ Improve customer satisfaction while reducing operational costs
✓ Translate Lean principles into practical actions in production, service and healthcare
✓ Collaborate with participants from diverse sectors to gain new perspectives
Agenda
This 12-day program is structured in two major modules, each designed to deepen understanding and develop practical capability in Lean strategy, value stream analysis, tools and transformation.
Module 1Lean Foundations & Green Belt in Lean Toolkit (8 days)
Day 1 – Introduction to Lean and Core Principles
Participants explore the origins of Lean, its strategic purpose and the key principles behind the Toyota Production System. Includes a LEGO simulation to experience flow, waste and continuous improvement.
Days 2–3 – Basic Value Stream Mapping in Manufacturing
Training in mapping the value stream from raw material to finished product. Participants learn how to design a future state based on Lean design principles instead of brainstorming.
Day 4 – Problem Solving (Toyota Business Practice)
A practical session led by a former Toyota master trainer. Participants learn the 8-step method, PDCA, A3 and 5 Whys using a case study.
Day 5 – Operational Stability: Jidoka & TPM
Focus on equipment reliability, OEE, quality at the source, Poka Yoke, Andon and the concept of autonomation.
Day 6 – Standard Work, 5S and Pull/Kanban
How stability supports flow and improvement. Introduction to pull systems, Kanban and workplace organisation.
Day 7 – Lean in Office & Service Environments
How to apply Lean outside production. Introduction to Business Process VSM for transactional processes.
Day 8 – BPVSM & SMED
Continuation of office VSM and an in-depth session on SMED supported by proven methodologies from over 150 improvement projects.
Module 2Designing the Lean Organisation (4 days)
Day 9 – Human Resources Development & Change Management
How HR supports Lean implementation. Includes guest lectures from Toyota and experts in administrative Lean transformation.
Days 10–11 – Value Stream Costing & Financial Flow Analysis
Participants learn how traditional accounting hides flow improvements and how Value Stream Costing and Throughput Accounting reveal true financial impact. Includes two case studies.
Day 12 – Lean Operating Systems & Culture
Daily Management systems illustrated through a Mars Food Europe case.
Lean culture development explained through a Johnson & Johnson (Janssen) case delivered by the GM Manufacturing.
Target audience
This programme is designed for managers, improvement leaders and professionals responsible for operational excellence, transformation and performance improvement across sectors.
Production & Industry
• Production managers
• Quality managers
• Supply chain and logistics managers
• Team leaders and supervisors
• Engineers and project leaders
• Employees wishing to contribute to improvement teams
Offices & Services
• Department managers
• Office managers
• Middle and senior management
• Self-employed professionals
• Anyone looking to improve administrative and transactional flows
Healthcare
• Functional managers
• Quality managers
• Department heads
• Prevention officers
• Healthcare professionals who want to improve patient-oriented processes
Trainers
Programme director and owner of Lean Academy
Dirk Van Goubergen
Prof. Dr. Ir. Dirk Van Goubergen has more than 30 years of practical and academic experience in industrial engineering, operations management, Lean/operational excellence and value stream design. He has worked with leaders and teams worldwide at organisations including Toyota Motor Europe, Volvo, Mars, Philips, Amazon, Daikin, TE Connectivity, Johnson & Johnson and Delphi Technologies.
Former HR Manager and Master Trainer at Toyota Motor Europe
Jan Hermans
Jan is a master trainer for Toyota Global Content programmes including PDCA, Performance Management, A3 Consensus Building & Communication and Problem Solving. He was a Management & Leadership Development specialist at Toyota Motor Europe and brings direct Toyota experience to the courses.
Senior trainer/coach at Van Goubergen P&M - Lean Academy
Herman De Rom
Herman worked at Volvo Cars as Head of Logistics Engineering, Operations Director and Group Senior Lean Director. He was also Operations Director at INEX. At Lean Academy he supports sessions on Total Productive Maintenance (TPM), flow and operational excellence.
Senior trainer/coach at Van Goubergen P&M - Lean Academy
Raf Mues
Raf is a certified master trainer in Toyota Global Content and TPS programmes including TBP, Hoshin Kanri and A3/PDCA Thinking. Before joining Lean Academy, he spent almost 30 years working with TPS and the Toyota Way at Toyota Motor Europe in several operational management roles.
Head of EMEA CAR T Operations at Johnson & Johnson
Bart Van Waeyenberge
Bart is a member of the Beerse Campus Management Committee and the boards of Janssen Pharmaceutica NV and ETiON. He has held local and international roles in Europe and the United States across process industry, automation, operations, supply chain and business excellence.
Lean Manager at Mars Food Europe
Patrick Wilms
Patrick has almost 30 years of experience with Lean at Mars, formerly Masterfoods. He brings practical expertise in standards, daily management and leadership development.
Certification
Theory exam GB in Lean
✓ 50 multiple choice questions – 90 minute (physical presence)
✓ Incl 1 re-examination
Practical exam
✓ Effective application of 1 problem solving initiative using the TBP/A3 methodology. This application is judged by a jury.
✓ Presentation of a strategic plan to implement Lean in your own organisation or department for the next 3 years, with demonstrated results and learnings from the first 6 months (PDCA)
✓ Incl. 1 re-examination
For additional exams there is an administrative fee of 250€ per exam.
Practical details and subsidies
Discounts
Organisations registering multiple participants for the same trainings sessions on the same dates benefit from the following reductions:
Second participant: 5%
Third participant: 10%
Fourth and subsequent participants: 15%
Subsidies
For participants from Flanders (Belgium):
KMO Portefeuille Registration Number Van Goubergen P&M : DV.O100454 (‘Personeelsmanagement’)
Number of Training Hours : 72 Hours – Maximum subsidy amount : 5.142 euro
Number of Training Hours (if already GB in Lean from Lean Academy) : 24 Hours – Maximum subsidy amount : 1.905 euro
Click here for more information
For participants from food industry (Belgium):
This training is also supported by Alimento/IPV for organisations in food industry in Belgium.
Please indicate on the registration form which subsidies you apply for.
Drinks and Meal
Residential Kick-Off in Blankenberge
Cold and hot drinks during the day are included in the training fee, as well as lunch and dinner.
Roosenberg sessions:
Cold and hot drinks are included in the training fee.
A light meal is served around 16:45.
Sessions typically run from 13:30 to 20:30, unless otherwise stated.
Location
The residential 3 day kick-off takes place at Hotel Aazaert, Blankenberge. Hotel cost at a reduced group rate needs to be paid by the participant at the hotel.
The rest of the training takes place at Roosenberg, Patotterijstraat 1, 9250 Waasmunster, where free parking is available.
Optional
COACHING
Additionally to our open training we offer optional individual off-line coaching during or after the training. The cost is 960 euros excluding VAT for 4 sessions of 1 hour. Alternatively we can provide, on simple request, a time budget for the (on/offline) coaching and further follow-up.
Possible follow-up courses include:
• Black Belt in Lean
• Hoshin Kanri
Contact
Feel free to contact us for
questions related to our
training. You can also check out
our FAQ.
Are you looking for in-company
training? Drop us a message on
academy@vangoubergen.com
and we will get back to you.
