Lesson Plan

• Describe the core lean concepts of Kaizen, quality circles, simultaneous engineering, cell production, JIT and waste management.
• Analyse how each strategy reduces waste and improves efficiency in a manufacturing setting.
• Apply a simple value‑stream map to identify waste and propose appropriate lean interventions.
• Evaluate the impact of lean implementation on lead time, inventory and product quality.

• Projector and screen
• PowerPoint slides summarising each lean tool
• Printed value‑stream map worksheets (blank and example)
• Sticky notes and markers for quality‑circle activity
• Kanban card templates
• Handout of the 8 wastes (Muda) table

Begin with a short video clip showing a chaotic factory floor versus a streamlined lean line to hook interest. Ask students what they think caused the difference, linking to prior knowledge of production layouts. Explain that today they will explore six lean tools and how to measure their success.

1. Do‑now (5’) – Quick quiz on traditional vs. lean production terminology (Kahoot).
2. Direct instruction (15’) – Present Kaizen, quality circles, simultaneous engineering, cell production, JIT and waste management with real‑world examples.
3. Group activity (20’) – In small groups, students create a simple value‑stream map of a fictitious product, identify at least three wastes, and suggest a lean tool to address each.
4. Quality‑circle simulation (10’) – Teams use sticky notes to propose improvements, then practice the 5 Whys to root‑cause a selected problem.
5. Check for understanding (5’) – Exit ticket: “Name one lean tool and the specific waste it eliminates.”
6. Plenary (5’) – Recap key take‑aways and preview next lesson on lean metrics.

Summarise how each lean strategy contributes to waste reduction and faster delivery. Collect exit tickets to gauge understanding and assign a short homework: students must find a real‑world example of a company using one of the lean tools discussed.