Learn how to apply key elements of Lean Production, from minimizing inventory and reducing setup times, to using 5S and Kaizen, in order to improve quality and productivity in your workplace.

About this course

Learn about Lean Management, a customer-centric methodology that improves processes by eliminating waste and focusing on value-added tasks.

This course will introduce the main tenets of the Toyota Production System, which includes Just-in-Time manufacturing, quality management tools, and the critical concept of Kaizen, the Japanese practice of continuous improvement. You will also learn about the key organization and managerial approaches that are used in Lean.

You will learn how to analyze process flows in order to establish process capacity and identify the process bottleneck. You will then calculate resource utilization and cycle time to evaluate the impact of set up times, batching, defects and reworks on key process performance measures, including inventory, flow rate and flow time.

We will also discuss the impact of key concepts of Lean, including Heijunka, Kanban, Jidoka, Andon, Poka Yoke, and 5S, which help achieve increased productivity and quality.

Upon successful completion of this program, learners will earn the TUM Lean and Six Sigma Yellow Belt certification, confirming mastery of Lean Six Sigma fundamentals to a Yellow Belt level. The material is based on the American Society of Quality (www.asq.org) Body of Knowledge up to a Green Belt Level. The Professional Certificate is designed as preparation for a Lean Six Sigma Green Belt exam.

What you'll learn

  • The history and background of Lean production and the complementing elements of quantity and quality control.
  • To measure production performance and how defects and waste degrade performance.
  • To understand the importance and role in Lean Production of the customer "Takt."
  • To improve process performance through the application of Lean principles, including setup time reduction, batch optimization, and defect elimination.
  • To explain the importance of Total Productive Maintenance and the widely-used metric Overall Equipment Effectiveness.
  • To understand the difference between push- and pull-systems and how the implementation of pull systems reduces waste.
  • To apply elements of Lean production including Heijunka, Kanban, Jidoka, and Poka-Yoke.
  • To apply the 5S methodology for establishing and sustaining a productive work environment.

Course Syllabus

Week 1: Introduction: Identification of Waste

Understand the basic differences between craft production and mass production. Review the history of Lean Production, focusing on Japan's Toyota Production System as an alternative to mass production. Discuss how waste impacts productivity and describe Taiichi Ohno’s famous 7 Wastes.

Week 2: Understanding Flow: Capacity Analysis

Cover the basics of process analysis, including understanding how to calculate process capacity and resource utilization, as well as the important concepts of cycle time and takt time. Understand the relationship between inventory, a waste, is directly related to the flow time in a system through Little’s Law. Understand how variability in a system causes queuing or waiting. even if there is enough capacity on average.

Week 3: Continuous Flow: Setup Time Reduction

Calculate the impact of setups on capacity when the product variety is increased and understand how batching can improve this, but at the expense of increased inventory. Review the Single Minute Exchange of Die (SMED), and learn why reducing setups and changeovers are critical to Lean manufacturing. Discuss the concept of Total Productive Maintenance and calculate the metric Overall Equipment Efficiency.

Week 4: Improving Flow: Workplace Organisation and Visualization

Introduction to the concepts of Workplace Visualization and Organization and 5S for improving and maintaining continuous flow in Lean Production.

Week 5: Maintaining Flow: Establishing Pull Systems and Scheduling

Define the key principle from the Toyota Production System, Just-In-Time (JIT)and the significance that JIT has for Lean Production in reducing waste and meeting customer demand. Review the relevant components of production planning and how these affect Production Scheduling, the heart of Lean Production. Understand, with the help of reduced setup time, how Mixed-Model Scheduling achieves a match between production and customer and how Pull systems can be realized using Kanbans.

Week 6: Quality and Continuous Improvement

Calculate the impact defects have on our flow rate. Understand how Poka Yokecan helps fool-proof our processes and learn how to structure and run a Kaizen Blitz to bring about rapid improvement opportunities for problem-solving and process improvements. Consider the central role of Continuous Improvement in Lean Production by comparing the set of management principles, The Toyota Way 2001, and Jeffrey Liker’s 14 Management Principles.

Prerequisites

This course reviews the basic calculations used in production management. Therefore, basic math skills are necessary.

Further Information

  • Length: 6 Weeks
  • Effort: 3–4 hours per week
  • Price: FREE; Add a Verified Certificate for $99 USD
  • Institution: TUMx
  • Subject: Business & Management
  • Level: Introductory
  • Language: English
  • Video Transcript: English
Program taught in:
  • English
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Last updated September 30, 2019
This course is Online
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