Course Overview

    Overview

    Course Highlights

    Eligibility Criteria

    Benefits

    What Lean Manufacturing Is and Why It Matters in MaltaBuilt Around the Toyota Production System

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    Key Highlightof the Lean Manufacturing Training Course

    Lean Manufacturing Training EligibilityWho Can Enroll?

    Why Lean Skills Pay off on Malta's Shop FloorsPractical Gains for People and Plants

    Where Lean Skills Take You in MaltaRoles, Sectors and Demand Now

    Lean manufacturing skills are in steady demand across Malta's industrial base, from pharmaceutical and medical device plants to semiconductors, aviation MRO and automotive component makers. As firms face tight labour markets, island logistics and rising cost pressure, professionals who complete Lean Manufacturing training and can eliminate waste and improve flow stand out for roles from Production Supervisor to Operations Manager. Here is what the Maltese market is telling us right now.

    Industry Pressures Making Lean Skills Essential in Malta

    Lean Manufacturing is a career and plant multiplier. Join Malta's manufacturing professionals who cut waste, speed up flow and raise plant performance. Start your Lean journey today.

    Your Malta Career Transformation

    Where You Stand Today

    What Lean Skills Change on the Shop Floor

    Malta's manufacturing sector is modernising under cost, quality and lead-time pressure, and employers increasingly separate professionals who can run Lean improvement from those who cannot. Here is which side of that line you want to be on.

    Sources: PayScale, Glassdoor, ERI SalaryExpert (Malta) 2026.

    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 Malta 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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    The Lean Tools You Will Put to WorkA Complete Practical Toolkit for the Shop Floor

    This Lean Manufacturing programme builds a complete, practical toolkit you can apply immediately. By the end of the day you can identify waste, map value streams, run 5S, design pull systems, calculate OEE and lead Kaizen improvement in your own plant.

    Identify and Eliminate the Eight Wastes

    Use the DOWNTIME framework (Defects, Overproduction, Waiting, Non-utilised talent, Transportation, Inventory, Motion, Extra processing) to spot and quantify waste on the Gemba, so you can target the improvements that matter most.

    Map a Value Stream

    Build current-state and future-state value stream maps, calculate takt time, find the bottleneck and identify push versus pull flows, giving you a clear roadmap for Lean improvement.

    Organise Any Workplace with 5S

    Apply Sort, Set in Order, Shine, Standardise and Sustain, plus visual management tools such as Andon and production boards, to create a clean, safe and productive work area.

    Design Pull Systems and Kanban

    Move from forecast-driven push to demand-driven pull, size Kanban loops and supermarkets, and apply Just-in-Time thinking to cut overproduction and inventory.

    Raise Reliability with TPM and OEE

    Apply Total Productive Maintenance and calculate Overall Equipment Effectiveness (Availability x Performance x Quality) to attack the six big losses and reach world-class equipment performance.

    Standard Work, SMED and Kaizen

    Document standard work, slash changeover time with SMED, level production with Heijunka, mistake-proof with Poka Yoke, and lead Kaizen continuous improvement that sustains the gains.

    Who Should TakeLean Manufacturing Training in Malta?

    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 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 Malta 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 Malta 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

    EUR 300

    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 Learning for Your Lean TrainingPractical, Expert-Led and Flexible

    Invensis Learning delivers practical, instructor-led Lean Manufacturing Training for professionals and organisations across Malta who want to eliminate waste, improve flow and build a continuous improvement culture. Our programmes combine experienced trainers, hands-on exercises and a complete Lean toolkit grounded in the Toyota Production System. Whether you enrol as an individual or arrange training for your plant team, we focus on real-world application and measurable results, backed by ISO 9001:2015 and ISO 27001:2022 certification.

    • Experienced, industry-practitioner trainers who have applied Lean on real production floors
    • Flexible formats: online (live virtual), classroom and onsite corporate delivery
    • Hands-on exercises using your own production scenarios, not just theory
    • Structured, practical courseware covering the full Lean toolkit
    • ISO 9001:2015 certified for quality management and ISO 27001:2022 for information security
    • Global training provider with local support across 100+ countries including Malta
    • Dedicated learner support before, during and after training
    • Course completion certificate recognising your Lean capability

    500+

    Corporate Clients

    15+

    Years of Training Excellence

    24/7

    Learner Support

    50+

    Industries Served

    ISO 9001:2015 Certified

    ISO 9001:2015 Certified

    ISO 27001:2022 Certified

    ISO 27001:2022 Certified

    Secure SSL Encryption

    Secure SSL Encryption

    Leaders in Training industry for 12+ years

    Leaders in Training industry for 12+ years

    Over 5000 five star reviews

    Over 5000 five star reviews

    Level AA conformance, W3C WCAG 2.2

    Level AA conformance, W3C WCAG 2.2

    Lean Manufacturing Training Locations in MaltaInstructor-led in-person Classroom training is available for group batches. All other public cohorts are delivered as Instructor-led Live Virtual. See available cohorts.

    Lean Manufacturing Training Location in Malta

    Hilton Malta, Portomaso Avenue, St. Julian's, Eastern Region, STJ 4012, Malta

    Lean Manufacturing Training Location in Malta

    InterContinental, St. George Street, St. Julian's, Eastern Region, STJ 3310, Malta

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    Corporate Lean Manufacturing Training in MaltaUpskill Your Team

    • Suitable for small production teams or entire plant workforces
    • Onsite, live virtual or hybrid delivery around shift patterns
    • Exercises built on your own value streams and production data
    • Trainers with real manufacturing and operational excellence experience
    • Consistent Lean practice standardised across sites and shifts
    • Dedicated coordination and learner support for group programmes
    • Scalable delivery for teams across Malta and international sites

    Leading Malta Manufacturers

    STMicroelectronicsPlaymobil MaltaToly ProductsTrelleborgMethode ElectronicsBaxter

    What Our Learners Say

    Waste I Could Finally See and Fix

    "The waste walk and value stream mapping exercises changed how I look at our line. Within a week I had cut two changeovers and freed up floor space using 5S. Genuinely practical training."

    Mark Borg

    Manufacturing Engineer

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    Confident Leading 5S and Kaizen

    "As a shift supervisor I now run short Kaizen huddles and a proper 5S audit. The trainer used real production examples, so everything applied straight away on the shop floor."

    Maria Camilleri

    Production Supervisor

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    Strong on Quality and Flow

    "The Poka Yoke and standard work sessions were spot on for our GMP environment. I came away able to explain OEE and the eight wastes to my team clearly."

    Daniel Vella

    Quality Engineer

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    Our Whole Team Speaks Lean Now

    "We ran the onsite programme for two production teams. The shared vocabulary around pull systems and waste has already reduced inventory and firefighting. Well organised and tailored to our plant."

    Claire Attard

    Operations Director, Electronics Manufacturer

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    Practical Upskilling That Stuck

    "Invensis tailored the training to our value streams and shift patterns. Supervisors are now leading their own improvement work, which was exactly the outcome we wanted for the team."

    Joseph Farrugia

    Plant Manager, Medical Devices

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    We also deliver Malta Certification Training across multiple cities

    Invensis Learning delivers industry-leading Lean Manufacturing training solutions tailored for individuals and organizations.

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

    Lean Manufacturing Training is a practical one-day (8-hour) programme that teaches you to eliminate waste, improve flow and deliver more value to customers using the Toyota Production System and the five Lean principles. It covers the eight wastes, value stream mapping, 5S, Kanban, JIT, TPM, OEE, standard work, SMED and Kaizen.