Course Overview

    Overview

    Course Highlights

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    What Does Lean Manufacturing Deliver on the Factory Floor?A Practical Route to Leaner Production

    Lean Manufacturing Training in Fiji is a practical, one-day programme that teaches production teams how to strip waste out of their operations and deliver more value to customers. Rooted in the Toyota Production System (TPS) and its five Lean principles, the course shows you how to identify value, map the value stream, create flow, establish pull and pursue continuous improvement. This is a hands-on skills course with no formal assessment. Across eight hours you work through the eight wastes (DOWNTIME), value stream mapping, 5S, kanban and Just-in-Time, Total Productive Maintenance, standard work and Kaizen, applying each tool to realistic factory scenarios. It suits production managers, engineers, supervisors, quality staff and Lean coordinators across Fiji's food processing, beverage, garment and sugar industries. Delivered by Invensis Learning in live virtual, classroom and on-site formats, the training turns Lean theory into shop-floor capability you can use from day one. Start building leaner, faster and lower-cost production with Invensis Learning.

    What Does Lean Manufacturing Deliver on the Factory Floor?A Practical Route to Leaner Production

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    Key Highlightof the Lean Manufacturing Training Course

    Lean Manufacturing Training EligibilityWho Can Enroll?

    The Real Value of Learning LeanFor You and Your Plant

    Where Lean Skills Take Your Career in FijiRoles, Demand and Pay

    Lean skills, and the Lean Manufacturing training that builds them, are increasingly valued across Fiji's manufacturing base, from food and beverage processing to garments, mineral water bottling and sugar milling. As import-reliant plants fight to protect margins and meet export standards, employers want people who can remove waste, lift equipment uptime and improve flow. Demand runs from shop-floor supervisors and manufacturing engineers up to production and operations managers, and here is what the local market looks like now.

    Why Fiji's Factories Are Turning to Lean

    Lean is more than a set of tools. It is a way to help Fiji's factories compete on cost, quality and speed. Join the professionals turning waste into value on the shop floor. Start your Lean journey today.

    Your Fiji Career Transformation

    Where You Stand Today on the Factory Floor

    Your Lean Transformation

    Fiji's manufacturers are under real pressure from imported inputs, a small home market and demanding export buyers, and they increasingly reward the people who can make production leaner. Here is which side of that line you want to be on.

    Sources: SkyPlanner, Paylab, Glassdoor, PayScale (Fiji) 2025-2026.

    Module 1: Foundations of Lean Thinking

    • Overview of the Toyota Production System (TPS), the history of Lean, and how Lean thinking differs from traditional mass production approaches
    • Understanding the five Lean principles: Value, Value Stream, Flow, Pull, and Perfection, and how they apply to manufacturing and service environments
    • Introduction to Lean culture, the leadership role in Lean transformation, and the importance of employee engagement in sustaining continuous improvement

    Module 2: Identifying and Eliminating Waste (MUDA, MURA, MURI)

    • Identifying the eight types of waste: Defects, Overproduction, Waiting, Non-Utilised Talent, Transportation, Inventory, Motion, and Extra Processing
    • Conducting waste walk exercises to assess current-state operations and prioritise improvement opportunities across production processes
    • Understanding the difference between MUDA (waste), MURA (unevenness), and MURI (overburden), and applying structured elimination strategies for each

    Module 3: Value Stream Mapping (VSM)

    • Creating current-state value stream maps to visualise the flow of materials and information across the production process
    • Analysing current-state maps to identify bottlenecks, excess inventory, non-value-added steps, and process cycle efficiency metrics
    • Designing future-state value stream maps and building improvement roadmaps to close the gap between current and desired production performance

    Module 4: 5S Workplace Organisation

    • Implementing the five steps of 5S: Sort (Seiri), Set in Order (Seiton), Shine (Seiso), Standardise (Seiketsu), and Sustain (Shitsuke)
    • Conducting 5S workplace assessments, scoring production areas, and identifying corrective actions to improve organisation and visual management
    • Building 5S sustaining mechanisms including audit schedules, visual controls, and standard work documentation to maintain workplace improvements

    Module 5: Just-in-Time (JIT) Production and Kanban

    • Understanding Just-in-Time production principles including Takt Time analysis, one-piece flow, and pull-based scheduling to reduce inventory and lead times
    • Designing and implementing Kanban pull systems to manage material flow, signal replenishment, and eliminate overproduction between production stages
    • Calculating Takt Time, cycle time, and process lead time to balance workload and design efficient production flows aligned with customer demand

    Module 6: Kaizen and Continuous Improvement Events

    • Understanding Kaizen philosophy, the PDCA (Plan-Do-Check-Act) improvement cycle, and the principles of rapid improvement event facilitation
    • Planning, facilitating, and following up on structured Kaizen events including team selection, problem scoping, root cause analysis, and countermeasure implementation
    • Building a Kaizen culture through daily improvement habits, idea management systems, and leadership behaviours that sustain continuous improvement momentum

    Module 7: Error-Proofing with Poka-Yoke and Jidoka

    • Understanding error-proofing principles and the difference between detection and prevention approaches to quality control in manufacturing processes
    • Designing and implementing Poka-Yoke (mistake-proofing) devices and mechanisms to eliminate defects at the source before they reach the next production stage
    • Applying Jidoka (autonomation) principles to enable machines and operators to detect abnormalities, stop production, and signal for corrective action automatically

    Module 8: Total Productive Maintenance (TPM) and OEE

    • Understanding Total Productive Maintenance principles including the eight pillars of TPM and how TPM supports Lean production by eliminating equipment-related waste
    • Calculating Overall Equipment Effectiveness (OEE) using Availability, Performance, and Quality components to measure and improve production asset performance
    • Implementing Autonomous Maintenance practices to involve operators in basic equipment care, inspection, and early defect detection to reduce unplanned downtime

    Module 9: Sustaining Lean and Building a Lean Culture

    • Developing Lean management systems including visual management, daily team meetings, tiered accountability processes, and leader standard work to sustain improvements
    • Measuring and tracking Lean progress using key performance indicators including lead time, first-pass yield, OEE, inventory turns, and on-time delivery
    • Building a long-term Lean transformation roadmap, engaging cross-functional teams, and developing internal Lean practitioner capability to drive ongoing operational excellence

    Course Curriculumof the Lean Manufacturing Training

    The Lean Manufacturing training curriculum in Fiji is structured across nine modules, taking learners from foundational Lean thinking and waste identification through to advanced production system design, error-proofing, and sustaining continuous improvement culture.

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    Skills You Will Build in This ProgrammeTools You Can Use on Monday Morning

    Skills covered in Lean Manufacturing training run the full Toyota Production System toolkit. By the end of the day you can run a waste walk, sketch a value stream map, set up 5S, size a kanban system, calculate OEE and lead a Kaizen improvement on your own shop floor.

    See and Eliminate the Eight Wastes

    Identify the eight wastes (DOWNTIME) through Gemba waste walks, then quantify and prioritise them so you target the losses that cost your plant the most.

    Map the Value Stream End to End

    Draw current and future-state value stream maps, calculate takt time, find the bottleneck and design smoother flow from raw material to finished goods.

    Organise the Workplace with 5S

    Apply Sort, Set in Order, Shine, Standardise and Sustain, plus visual management such as Andon and production boards, to make abnormalities visible at a glance.

    Design Pull Systems and Kanban

    Move from push to pull, size kanban loops and supermarkets, and apply Just-in-Time thinking to curb overproduction and cut work-in-progress inventory.

    Lift Reliability with TPM and OEE

    Use Total Productive Maintenance and autonomous maintenance, and calculate Overall Equipment Effectiveness across availability, performance and quality to target the six big losses.

    Apply Standard Work, SMED and Kaizen

    Write standard work, cut changeover time with SMED, level production with Heijunka and run Kaizen improvements that build a lasting continuous improvement culture.

    Who Should TakeLean Manufacturing Training in Fiji?

    Manufacturing Managers and Plant Managers

    Production Supervisors and Team Leaders

    Quality Engineers and Quality Managers

    Industrial Engineers and Process Engineers

    Supply Chain and Operations Professionals

    Maintenance Engineers and TPM Coordinators

    Professionals transitioning into Lean or process improvement roles

    Continuous Improvement (CI) and Operational Excellence Specialists

    Who Can Take This Certification Training

    Lean Manufacturing Training Modesfor Professionals and Teams

    We offer flexible training formats designed to suit different learning preferences, schedules, and professional goals. Whether you prefer self-paced learning or a structured, corporate, instructor-led experience, choose the option that best supports your skill development journey with the best Lean Manufacturing online training options.

    Lean Manufacturing Live Virtual Training

    • Live online instructor-led sessions

    • Interactive discussions and virtual activities

    • Expert guidance from experienced trainers

    • Practice assessments and revision support

    • Dedicated Q&A sessions for concept clarification

    • Fixed schedules for accountability and momentum

    • Small batch sizes for personalized attention

    • Access from any location with internet connectivity

    FJD 830

    Attend fully interactive online sessions from anywhere while benefiting from real-time instructor guidance and collaborative learning experiences through virtual Lean Manufacturing training.

    Best For: Professionals seeking the flexibility of online learning without compromising on live instructor interaction.

    Lean Manufacturing Classroom Training

    • Instructor-led classroom sessions

    • Interactive discussions and group activities

    • Real-world examples and practical exercises

    • Structured learning with fixed schedules

    • Opportunities for peer networking and collaboration

    • Practice assessments and knowledge checks

    • Dedicated Q&A and concept clarification

    • Immediate trainer feedback and support

    Learn through face-to-face sessions led by experienced instructors in a collaborative classroom environment. This classroom Lean Manufacturing training in Fiji combines expert guidance, peer interaction, and hands-on activities to create an engaging learning experience.

    Best For: Learners who prefer in-person interaction, structured schedules, and collaborative learning experiences.

    Lean Manufacturing Corporate Group Training

    • Customized training aligned to organizational goals

    • Flexible delivery: onsite, virtual, hybrid, or blended

    • Scheduling tailored to business availability

    • Role-based examples and industry-relevant discussions

    • Progress tracking and learner assessments where applicable

    • Dedicated coordination and administrative support

    • Consistent learning experiences across teams

    • Scalable delivery for local, regional, or global workforces

    Designed for organizations in Fiji that want to build capabilities at scale, standardize Lean practices, and support workforce development through customized Lean Manufacturing training for companies.

    Best For: Organizations looking to upskill employees, address capability gaps, and deliver consistent training across teams.

    Lean Manufacturing Focused 1-to-1 Training

    • One-to-one instructor attention

    • Customized learning plans and objectives

    • Flexible scheduling based on availability

    • Personalized feedback and coaching

    • Additional focus on challenging topics

    • Targeted practice and revision support

    • Faster clarification of questions and concepts

    • Learning pace is adapted to individual needs

    Receive personalized instruction tailored to your goals, pace, and learning requirements through dedicated sessions from trusted Lean Manufacturing training company.

    Best For: Professionals seeking personalized guidance, accelerated learning, or focused support to achieve specific outcomes.

    Lean Manufacturing Live Virtual Training

    Lean Manufacturing Live Virtual Training

    Live online instructor-led sessions

    Interactive discussions and virtual activities

    Expert guidance from experienced trainers

    Practice assessments and revision support

    Dedicated Q&A sessions for concept clarification

    Fixed schedules for accountability and momentum

    Small batch sizes for personalized attention

    Access from any location with internet connectivity

    Starts from

    FJD 830

    Please Note: Attend fully interactive online sessions from anywhere while benefiting from real-time instructor guidance and collaborative learning experiences through virtual Lean Manufacturing training.

    Best For: Professionals seeking the flexibility of online learning without compromising on live instructor interaction.

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    Why Choose Invensis LearningFor Lean Manufacturing Training in Fiji

    As a Lean Manufacturing training company in Fiji, Invensis Learning delivers practical Lean training for professionals and teams who want to remove waste and improve production performance. Our programmes combine experienced practitioner trainers, hands-on exercises and structured courseware built on the Toyota Production System. Whether you enrol as an individual or arrange corporate training for your plant, you get a professional learning experience focused on real shop-floor application and measurable improvement, backed by our ISO 9001:2015 and ISO 27001:2022 certified operations.

    • Experienced trainers with real manufacturing and Lean practitioner backgrounds
    • Flexible formats for individuals, teams and corporate groups
    • Hands-on exercises using waste walks, VSM, 5S and OEE calculation
    • Structured, easy-to-follow courseware grounded in the Toyota Production System
    • Live virtual, classroom and on-site delivery to suit your schedule
    • Customised group programmes built around your own production processes
    • Dedicated learner support before, during and after training
    • ISO 9001:2015 and ISO 27001:2022 certified training operations

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    Leaders in Training industry for 12+ years

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    Over 5000 five star reviews

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    Lean Manufacturing Training Locations in FijiAll our classroom training is now available online at your convenience

    Lean Manufacturing in Fiji

    Sofitel Fiji Resort & Spa, Fiji

    Lean Manufacturing in Fiji

    Hilton Fiji Beach Resort & Spa, Fiji

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    Corporate Lean Manufacturing TrainingFor Fiji Teams

    • Suitable for small, medium and large production teams
    • Training schedules aligned with your shift and plant availability
    • Flexible delivery through on-site, live virtual or hybrid formats
    • Exercises run on your own processes for immediate shop-floor value
    • Trainers with hands-on manufacturing and Lean improvement experience
    • Dedicated coordination and support for group training programmes
    • Scalable delivery for teams across Fiji and the wider Pacific

    Manufacturers We Can Support

    Goodman FielderFiji Sugar CorporationFiji WaterParadise BeveragesFlour Mills Of FijiPunjas

    What Our Learners Say

    Real Changes on the Line Within a Week

    "The waste walk and value stream mapping exercises opened my eyes. Within a week of the training I had cut two clear bottlenecks on our packing line and reduced waiting time between stations."

    Anil Prasad

    Production Supervisor, Food Processing

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    TPM and OEE Made Simple and Usable

    "I finally understand OEE and how the six big losses eat into our output. The TPM session gave me a practical way to work with maintenance and lift uptime on our older equipment."

    Litia Vakacegu

    Manufacturing Engineer, Beverage

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    Practical and Relevant to Our Plant

    "Very hands-on and well paced. The 5S and standard work parts were exactly what our quality team needed, and the trainer used examples that fit our kind of production."

    Reshmi Chand

    Quality Officer, Manufacturing

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    A Shared Lean Language Across the Plant

    "We trained a cross-functional team on-site and it created a shared Lean language across operators, supervisors and engineers. Kaizen ideas now come from the floor, not just management."

    Josaia Tuwai

    Operations Manager, Food and Beverage

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    Tailored Corporate Training That Stuck

    "As an L&D lead I valued how tailored the corporate session was. They built the exercises around our own processes, so the team could apply kanban and 5S the same week."

    Mereseini Naidu

    L&D Manager, Manufacturing Group

    0/0



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    Frequently Asked QuestionsHere's everything you may ask...

    Lean Manufacturing training is a one-day, hands-on skills course that teaches you to remove waste from production and deliver more value to customers. It is built on the Toyota Production System (TPS) and its five Lean principles, and covers tools such as 5S, value stream mapping, kanban, TPM and Kaizen.

    General

    What is Lean Manufacturing training?

    Lean Manufacturing training is a one-day, hands-on skills course that teaches you to remove waste from production and deliver more value to customers. It is built on the Toyota Production System (TPS) and its five Lean principles, and covers tools such as 5S, value stream mapping, kanban, TPM and Kaizen.

    Who should attend Lean training in Fiji?

    The course suits production and manufacturing managers, industrial and process engineers, supervisors, team leaders, quality staff, maintenance managers and Lean coordinators. It fits anyone in Fiji's food, beverage, garment or sugar industries who wants to apply Lean on the shop floor.

    Is Lean worth it for Fiji's manufacturers?

    Yes. With imported inputs, a small home market and strict export buyers, Fiji's plants compete on cost and quality, which is exactly what Lean improves. Trained people who can cut waste, lift uptime and improve flow are valued and hard to find locally.

    Do I need prior Lean experience to join?

    No. There are no prerequisites. The course introduces Lean manufacturing from first principles, so it works for newcomers as well as experienced professionals. Some production or operations background is helpful but not required.

    What framework is the training based on?

    The training is grounded in the Toyota Production System, developed at Toyota by Taiichi Ohno and Shigeo Shingo. It follows the five Lean principles and the eight wastes (DOWNTIME), with tools including VSM, 5S, kanban, Just-in-Time, TPM, standard work, SMED and Kaizen.

    Pricing

    How much does Lean training cost in Fiji?

    Fees depend on the delivery format, whether live virtual, classroom or on-site corporate, and on group size. Pricing is available on request. Speak with a learning advisor for a quote tailored to your needs.

    What is included in the course fee?

    The fee typically covers instructor-led delivery of all six modules, structured courseware, hands-on Lean exercises, downloadable templates, learner support and a course completion record from Invensis Learning.

    Do you offer group or corporate pricing?

    Yes. We offer corporate group training with schedules and content tailored to your plant, and volume-based pricing for teams. Contact us to ask about corporate or group rates for your organisation.

    What payment options are available?

    We accept major credit and debit cards and bank transfers, and can arrange invoicing for corporate bookings. Talk to a learning advisor to choose the option that suits you.

    Is there a discount for enrolling a whole team?

    Corporate and group bookings are priced by volume, so training a full team is more cost-effective per person than individual seats. Request a group quote and we will build a package around your headcount.

    Assessment

    Is there an exam for this course?

    No. This is a non-certification skills course with no examination. Learning is reinforced through hands-on exercises, waste identification activities and manufacturing case examples across the one-day programme.

    Do I receive anything on completion?

    Yes. You receive a course completion record from Invensis Learning that confirms you have completed the Lean manufacturing programme. It is not an external credential, but it evidences the skills you have built.

    How is learning checked during the course?

    There is no formal assessment. Instead you apply each tool as you learn it, through waste walks, value stream mapping, a 5S review, kanban sizing and an OEE calculation, so you practise on realistic scenarios before using them at work.

    Will I be able to apply Lean tools at work?

    Yes. By the end you can run a waste walk, map a value stream, set up 5S, design a kanban pull system, calculate OEE and lead Kaizen improvements. The tools are immediately usable on your own production lines.

    Do I need to renew anything afterwards?

    No. There is nothing to renew and the skills do not expire. Lean knowledge stays applicable, and you can extend it later with related courses such as Value Stream Mapping, Kaizen or Lean Six Sigma.

    Course Content

    What topics does the Lean course cover?

    The programme spans TPS foundations and the five Lean principles, the eight wastes, value stream mapping, 5S and visual management, pull systems and kanban, Just-in-Time, TPM and OEE, standard work, SMED, Heijunka, Poka Yoke and building a Lean culture.

    What Lean tools will I learn to use?

    You learn value stream mapping, 5S, kanban and supermarkets, Just-in-Time, Total Productive Maintenance with OEE, standard work, SMED quick changeover, Heijunka levelling, Poka Yoke mistake-proofing and Kaizen improvement.

    Are there hands-on exercises?

    Yes. Practical exercises run throughout the day, including a Gemba waste walk, value stream data collection, a 5S workplace assessment, kanban quantity calculation and an OEE calculation on realistic production data.

    How long is the training?

    The programme is delivered in one full day of eight hours, or as two half-days of four hours each. Both formats cover all six modules with the same hands-on exercises.

    What materials are provided?

    You receive structured courseware, exercise workbooks and downloadable Lean templates such as VSM symbols, 5S audit checklists and OEE worksheets, so you can reuse the tools directly on your shop floor.

    Enrollment

    How do I enrol in Lean training in Fiji?

    Enrol through the Invensis Learning website. Choose your preferred format, complete your booking, and you will receive schedule details, courseware and learning resources. Contact a learning advisor if you would like help choosing a batch.

    What training formats are available?

    We offer online (live virtual) instructor-led training, classroom sessions and on-site corporate delivery, so you can pick the format that fits your schedule and team. Self-paced options may also be available on request.

    Can the course be delivered on-site for my team?

    Yes. On-site corporate training is a popular choice for Fiji manufacturers, because the exercises can be run on your own processes. We tailor the content and schedule to your plant. Ask us about a group booking.

    How soon can I start?

    New batches run regularly, and corporate sessions can be scheduled around your team's availability. View upcoming schedules or talk to a learning advisor to find the next convenient date.

    Can I reschedule my enrolment?

    Yes. Flexible options let you move to another batch if your plans change. Contact our support team and we will help you rearrange your training to a date that works.