QQI Lean Manufacturing Tools

qqi-Lean Manufacturing

Transform your manufacturing organisation into a leaner enterprise.

The purpose of this 5-day QQI Level 5 award is to equip the learner with the knowledge, skill and competence to apply lean principles in a range of manufacturing environments and to use a range of lean manufacturing tools.

Learners attending this programme must meet RPL criteria. Your entry to this course is not guaranteed until The Cpl Institute training team can confirm your RPL eligibility.

If you are unsure of your eligibility contact us on 01 895 5755.

Click on the links below for information on RPL & Exemptions

On course completion learners will be able to:

  1. Discuss lean thinking to include the five lean principles, the seven wastes and the key differences between lean manufacturing and mass production
  2. Explore the benefits of good workplace organisation, the five steps (5S) of workplace organisation, sorting, straightening, sweeping, standardising and sustaining of practice and appropriate visual control systems
  3. Examine a basic Total Productive Maintenance (TPM) system and its benefits
  4. Analyse the elements of the Overall Equipment Effectiveness (OEE) metric
  5. Explore improvement cycles to include appropriate improvement tools, the differences between root causes, direct causes and contributing causes, appropriate corrective and preventive actions and the differences between incremental and breakthrough improvement
  6. Discuss the benefits of a timed delivery route and the four stages of the Single-Minute Exchange of Die (SMED) technique
  7. Summarise the elements of standard work
  8. Discuss quality, mistake-proofing and line layout to include the interaction between quality and lean manufacturing and appropriate mistake-proofing devices and line layout
  9. Construct a problem definition and Specific, Measurable, Attainable, Relevant and Timescale (SMART) objectives
  10. Recommend an appropriate Kanban system
  11. Calculate the number of Kanban cards required
  12. Reduce changeover time using Single-Minute Exchange of Die (SMED)
  13. Configure standard work for minimum use of labour, materials and equipment
  14. Identify appropriate situations, goals and teammembers for a Kaizen event
  15. Analyse the value-added and non-value-added activities in their own organisations
  16. Conduct process observation to determine element cycle times
  17. Employ value stream mapping to include the current status using a current state map and a future state map, describing desired improvements.

All learning outcomes must be assessed:

  • Skills Demonstration 60%
  • Assignment 40%

Skills Demonstration:

A skills demonstration is used to assess a wide range of practical based learning outcomes including practical skills and knowledge. A skills demonstration will require the learner to complete a task or series of tasks that demonstrate a range of skills.


An assignment is an exercise carried out in response to a brief with specific guidelines as to what should be included. An assignment is usually of short duration and may be carried out over a specified period of time.


  • Pass 50% – 64%
  • Merit 65% – 79%
  • Distinction 80% – 100%


Successful completion of this component award enables the learner to transfer to programmes leading to other certificates where this component is a mandatory or an elective requirement.


QQI Level 5 Lean Manufacturing Tools Certificate