Lesson Plan

• Describe how lean production reduces inventory levels and improves cash flow.
• Explain the impact of lean tools (5S, poka‑yoke, Kaizen) on quality and defect reduction.
• Analyse how employee empowerment and capacity‑matching (Heijunka, flexible cells) increase overall efficiency.

• Projector and screen
• Whiteboard and markers
• Handout summarising waste types and lean tools
• Kanban cards or printable symbols for a demo
• Worksheet with JIT calculation exercises
• Laptop with presentation slides

Begin with a short video clip showing a cluttered factory floor versus a tidy lean line to hook interest. Ask students what “waste” means in a business context, linking to prior knowledge of inventory costs. Explain that by the end of the lesson they will be able to identify lean impacts on inventory, quality, employee roles, capacity and overall efficiency.

1. Do‑now (5') – Quick quiz on differences between traditional and lean inventory systems.
2. Mini‑lecture (10') – Introduce lean principles, the seven wastes, and pull‑based production.
3. Interactive JIT calculation (10') – Students compute inventory levels using the formula Inventory = Demand × Lead Time.
4. Group activity (15') – Design a simple Kanban system with cards; each group presents its flow.
5. Role‑play (10') – Employees act as “process owners” to spot waste and suggest Kaizen ideas.
6. Whole‑class debrief (5') – Compare efficiency metrics (inventory turnover, defect rate, lead time) between traditional and lean setups.

Summarise how lean production links inventory control, quality, employee involvement, capacity management and overall efficiency. Students complete an exit ticket stating one lean tool they could apply in a real‑world business. Assign homework: create a one‑page checklist of lean actions for a chosen product or service.