Lesson Plan

• Describe the seven types of waste targeted by lean production.
• Explain how lean production supports business objectives such as cost reduction and customer satisfaction.
• Analyse the role of continuous improvement (Kaizen) in enhancing quality and flexibility.
• Apply a basic lean tool (e.g., 5S or Kanban) to a simulated production scenario.
• Evaluate the strategic benefits of lean production for competitive advantage.

• Projector and screen
• Whiteboard and markers
• Printed handouts of the lean tools table
• Sticky notes and index cards for 5S/Kanban activity
• Worksheet with a short case study
• Short video clip illustrating lean principles

Begin with a quick “spot the waste” brainstorm – ask students to list everyday examples of unnecessary effort or resources. Connect this to their prior learning about operations strategy and the need for efficiency. Explain that by the end of the lesson they will be able to identify lean’s key aims, link them to business goals, and demonstrate a simple lean tool.

1. Do‑now (5'): Students write three examples of waste they encounter at home or school on sticky notes and place them on the board.
2. Mini‑lecture (10'): Teacher presents the main aims and purposes of lean production, highlighting waste reduction, quality, flexibility, lead‑time, cost, customer satisfaction, and employee engagement.
3. Tool demonstration (15'): Live Value Stream Mapping of a simple product (e.g., a school snack) to visualise material and information flow and identify waste points.
4. Group activity (15'): In small groups, students use 5S and Kanban cards to reorganise a mock workstation, practising waste elimination and pull‑based signalling.
5. Check for understanding (5'): Quick quiz (Kahoot or handout) covering the seven wastes and the strategic benefits of lean.
6. Summary & transition (5'): Teacher recaps the objectives, highlights key take‑aways, and previews the next lesson on lean tools implementation.

Review the six aims of lean and ask students to write one sentence on how they would apply a lean principle in a real‑world context as an exit ticket. Collect the responses and remind the class that their homework is to research a company that uses lean production and prepare a brief summary of its impact on cost, quality, and flexibility.