AI for Lean Manufacturing
About This Course
This AI for Lean Manufacturing course equips learners with practical knowledge and hands-on skills to apply Artificial Intelligence (AI) to improve manufacturing processes, reduce waste, enhance productivity, and support continuous improvement. The course integrates established Lean Manufacturing principles with modern AI capabilities, enabling participants to identify inefficiencies, analyse operational data, and make more informed improvement decisions.
Learners will explore how AI can support key Lean practices such as value stream analysis, waste identification, process optimisation, quality improvement, predictive maintenance, production planning, and root cause analysis. Through practical manufacturing scenarios, participants will use AI to analyse process information, identify bottlenecks and non-value-added activities, generate improvement recommendations, and evaluate alternative solutions.
The course also examines how AI can enhance traditional Lean approaches such as 5S, Kaizen, Value Stream Mapping (VSM), Standard Work, Overall Equipment Effectiveness (OEE), and continuous improvement. Participants will learn how AI-assisted analysis can help uncover patterns in production data, monitor operational performance, anticipate potential issues, and support faster problem-solving.
With a strong emphasis on hands-on and real-life manufacturing applications, learners will work through practical exercises and improvement scenarios that demonstrate how AI can complement human expertise on the production floor. By the end of the course, participants will be able to apply Lean and AI techniques together to identify improvement opportunities, streamline manufacturing workflows, reduce operational waste, and contribute to smarter, more efficient manufacturing operations.
What You'll Learn
LO1 - Identify eight types of production wastes within the organisation, benefits of lean manufacturing and steps to achieve lean performance results.
LO2 - Apply lean principles to compute production capacity and TAKT time.
LO3 - Perform ABC analysis for inventory classification using selective inventory control
LO4 - Calculate economic batch quantity and number of ‘kanbans’ required.
LO5 - Identify objectives of production and inventory control and types of inventories by function and condition.
LO6 - Implement lean manufacturing tools for improved inventory flow and material flow
LO7 - Implement lean manufacturing in an organization at various levels and within various areas for improvement
LO8 - Determine the necessity for preventive maintenance within the organisation
LO9 – Identify performance measurement areas in lean manufacturing and steps required for successful lean implementation.
Course Outline:
Topic 1: AI-Assisted Lean Manufacturing Fundamentals and Waste Reduction
Topic 2: AI for Inventory Classification and Kanban Optimisation
Topic 3: AI-Enabled Production, Inventory and Material Flow Control
Topic 4: AI for Lean Implementation, Performance and Preventive Maintenance
Entry Requirements
Knowledge and Skills
• Able to operate using computer functions
• Able to operate using computer functions
• Minimum 3 GCE ‘O’ Levels Passes including English or WPL Level 5 (Average of Reading, Listening, Speaking & Writing Scores)
Attitude
• Positive Learning Attitude
• Enthusiastic Learner
Experience
• Minimum of 1 year of working experience