Lesson Plan

• Describe the key principles of lean production (JIT, Kaizen, pull system, waste elimination).
• Compare the advantages and disadvantages of lean production with traditional production methods.
• Analyse how lean practices affect inventory costs, quality, flexibility, and employee involvement.
• Apply the OEE formula to evaluate lean performance in a given scenario.
• Evaluate challenges of implementing lean production in different business contexts.

• Projector and screen for slides/diagrams
• Whiteboard and markers
• Handout summarising lean principles and TIMWOOD wastes
• Worksheet with case study and OEE calculation
• Sticky notes or cards for a Kanban simulation activity
• Laptop with internet access for a short video clip

Begin with a short video clip showing a smoothly running factory floor, prompting students to consider how waste is minimised. Ask learners to recall any prior knowledge of production methods and their impact on cost and quality. Explain that today they will investigate lean production, identify its benefits and drawbacks, and learn how to measure its effectiveness. Success will be demonstrated by accurately completing a lean‑performance worksheet.

1. Do‑now (5'): Quick mind‑map on “What makes a production system efficient?” – share ideas.
2. Mini‑lecture (10'): Present key lean principles (JIT, Kaizen, pull, TIMWOOD) using slides and a flow diagram.
3. Group activity (15'): Kanban simulation with sticky notes to illustrate pull system and identify waste.
4. Comparative analysis (10'): Students complete a table comparing lean vs. traditional production (handout provided).
5. OEE calculation practice (10'): Guided worksheet where learners compute Overall Equipment Effectiveness from sample data.
6. Plenary (5'): Whole‑class discussion summarising advantages/disadvantages; exit ticket – write one benefit and one challenge of lean production.

Recap the main features of lean production and how they translate into cost savings, quality gains and flexibility. Collect exit tickets to check understanding of one advantage and one disadvantage. Assign homework to research a real‑world company that has adopted lean methods and prepare a brief summary.