Lean Manufacturing A-Z: Operations Management & Six Sigma from Udemy

Master the tools and methodology of Lean, Six Sigma and Kaizen to have and "impact" and "improve" your business operations - manufacturing, services, industrial operations and production.
Covers the essentials of White Belt, Yellow Belt and many Green Belt Concepts of Lean and White > Yellow Belt Six Sigma.
Equip yourself to take a new leading role in your workplace - improving your processes, systems, business / organization.
Understand the fundamentals, then details of the most effective, proven improvement methodology ever. The principles, tools and essential approaches to continuous improvement / kaizen in business systems, organization and design.
Become the Lean & Six Sigma authority in your team on improving the operations systems in your business

This MBA style course on Lean Manufacturing & Six Sigma prepares and empowers you to make a REAL difference. Turbo-charge your career, and your business performance, to the highest levels.

This course is for the new or aspiring manager, the ambitious engineer, high flying consultant, the hands-on planners and the practical business analysts.

Business operations come in all shapes and sizes with a host of unique challenges; but Lean, whilst first developed in manufacturing has successfully lasted the decades and bridged into transport, retail, healthcare, logistics, finance and service companies. Lean remains the heart of continuously improving businesses of all types to remain competitive, improving profitability, improving customer experience and customer satisfaction, reducing costs and improving delivery.

Without a solid grasp of Lean and an awareness of Six Sigma, no manager, junior or senior, can competently or confidently look to improve their business operations, the processes, systems and teams that make a business successful.

Take control of your career and equip yourself with a solid base in Lean Methodologies that you can practically use right now to unlock the potential of your business processes.

Course Sections:

1. Lean Fundamentals and Philosophy

2. Value and Waste

3. Inventory Management and Control

4. Tools of Lean

5. Quality Management

6. Flow

7. Scheduling and Production Planning for Lean

8. History of Lean

Course Extras

Downloadable Documents with summaries and exercises
Summary Test with 80 multiple choice questions to test and lock in your learning

Take control. Boost your career and your business. Join us today.

Full List of Course Sub Sections:

1. Fundamentals and Philosophy of Lean

Fundamentals of Lean
The 5 Principles of Lean
Lean is like an Orchestra
Muda, Muri & Mura
The 25 Characteristics of Lean

2. Value and Waste

Value and Waste - Introduction
Finding Customer Value - Kano
Process Mapping for Value
Value Timelines
Tea Shop VA/ NVA Exercise
Tea Shop Exercise - Debrief
The 8 Wastes of Lean : TIMWOODS
Other Types of Waste
Chasing Waste - Caution

3. Inventory Management

Inventory Introduction
What is Inventory?
Why do we Need Inventory?
Little's Law
Costs of Inventory
Rock-Boat Analogy

4. Tools of Lean

Tools - Introduction
5S - Workplace Organization
SMED: Changeover and Cycletime Reduction
SMED Method: Gantt Chart
Value Stream Mapping (VSM)
Visual Management
Gemba
Gemba Walks
Standard Work
PDCA Improvement Cycle
A3 Reports

5. Quality

Quality - Introduction
Reducing Complexity
Reducing Mistakes
Reducing Variation
Root Cause and 5 Whys
Jidoka - Autonomation
Poka-Yoke - Mistake Proofing
Total Productive Maintenance (TPM)

6. Flow

Flow - Introduction
What Stops Flow?
Reducing Variation in the System
Causes of Variation of Demand and Capacity
Demand Management - Introduction
External Demand Management
Internal Demand Management
Takt Time, Cycle Time & Lead Time
Takt Time
Cycle Time
Throughput and Lead Time
Takt Time, Cycle Time & Lead Time Summary
Small Batch Sizes
Batch Sizes and One Piece Flow
Local Efficiencies don't make an efficient system

7. Scheduling and Pull

Scheduling - Introduction
Lean Scheduling
Choosing Batch Sizes
Economic Batch Quantity / EOQ / EBQ
Every Product Every Interval ( EPEI )
Pull
Cake Shop Example - Pull vs Push
Production Pull in a Burger Shop
Kanban - Production Planning
Push vs Pull Approaches
Pull: Pros and Cons
Push Pull Combination

8. History of Lean

History of Lean - Introduction
History of Lean - Timeline
Toyota Production System (TPS)

9. Six Sigma

Overview of Six Sigma
Six Sigma Statistics
Principles of Six Sigma
History of Six Sigma
Six Sigma Certification Belts
DMAIC Improvement Methodology
DMAIC Doughnut Example
Analysis Methods and Pitfalls
Analytical Tools in Six Sigma
Visualising Data
Comparing Lean and Six Sigma
Comparison of Lean and Six Sigma
Summary - Six Sigma

What's inside

Learning objectives

Become the lean & six sigma guru in your team! combine thorough understanding with powerful tools and techniques
Gain a total overview of lean operations for your manufacturing or service business
Boost your career: increase your confidence to see and lead change , impress your own boss and become a better manager
Six sigma fundamentals - 13 dedicated new lessons of this powerful quality improvement methodology
Increase profitability, improve delivery and use your resources more efficiently

Master the fundamentals of lean from total beginner to a competent professional. all the tools, principles and philosophy of lean
Practical actions on how to improve any operations business or process; from a factory to a restaurant
Enhance and organize your business more effectively and efficiently
Ideal for industrial / production / manufacturing organizations but also service and traditional business operations
An mba style module ideal for managers, consultants, planners, business analysts ,engineers and supervisors

Become the lean & six sigma guru in your team! combine thorough understanding with powerful tools and techniques
Gain a total overview of lean operations for your manufacturing or service business
Boost your career: increase your confidence to see and lead change , impress your own boss and become a better manager
Six sigma fundamentals - 13 dedicated new lessons of this powerful quality improvement methodology
Increase profitability, improve delivery and use your resources more efficiently
Master the fundamentals of lean from total beginner to a competent professional. all the tools, principles and philosophy of lean
Practical actions on how to improve any operations business or process; from a factory to a restaurant
Enhance and organize your business more effectively and efficiently
Ideal for industrial / production / manufacturing organizations but also service and traditional business operations
An mba style module ideal for managers, consultants, planners, business analysts ,engineers and supervisors

Syllabus

Fundamentals and Philosophy of Lean

Welcome

Fundamentals of Lean

The 5 Principles of Lean

Test your knowledge with this multiple choice test on the sections: Quality, Flow & Scheduling

Traffic lights

Read about what's good

what should give you pause

and possible dealbreakers

Covers the essentials of Lean's White Belt, Yellow Belt, and many Green Belt concepts, providing a solid foundation for those seeking to advance their knowledge and skills in operations management

Explores the Toyota Production System, which is the foundation of Lean methodologies and offers insights into its historical development and practical application in manufacturing

Examines both Lean and Six Sigma methodologies, which allows learners to understand the synergies between these approaches to process improvement and quality management

Includes a summary test with multiple-choice questions, which helps learners reinforce their understanding of the material and assess their progress

Requires learners to understand the fundamentals of Lean before diving into details, which may necessitate additional preparation for those with no prior exposure to operations management

Teaches concepts like Economic Batch Quantity (EBQ) and Every Product Every Interval (EPEI), which may require learners to have a basic understanding of mathematics and statistics

Reviews summary

Foundational lean & six sigma

According to learners, this course provides a clear and concise introduction to Lean Manufacturing and Operations Management principles. Many students found the explanations easy to understand and appreciated the practical applicability of the tools and techniques presented. The instructor is highly regarded for their knowledge and teaching style. While praised as a great starting point and ideal for beginners seeking foundational knowledge, some felt the course is basic in parts and could benefit from more in-depth coverage, particularly regarding Six Sigma concepts. A few reviewers noted that some material felt somewhat outdated. Overall, it is seen as a solid foundation for improving business operations.

Good introduction, but coverage is basic in some areas.

"it is a comprehensive introduction... Ideal for entry-level professionals"

"Good course overall, provides good foundational knowledge..."

"If you are looking for a quick overview course on Lean Manufacturing this one is for you."

"The course is quite basic... Not worth the time if you have some basic knowledge on Lean already."

Quizzes and tests aid in reinforcing concepts.

"The quizzes and assignments are great to reinforce the concepts."

"Also, the final test is a good way to check if you understood all the topics."

"The downloadable documents were useful."

Useful tools for real-world operations.

"The best feature is applicability of the techniques and processes to real world operations."

"I am applying it daily in my current role."

"This course has provided me with a valuable understanding of lean principles and tools that I can apply to my work."

"I found the tools and techniques useful for improving my work processes."

Concepts are well-explained and easy to follow.

"Great course, well explained and easy to understand."

"I found the course very clear and easy to understand, the explanations are very good..."

"Instructor is knowledgable and keeps the lessons concise and engaging."

"Very concise and clear explanation of lean manufacturing."

"excellent teaching and valuable knowledge"

Some materials or visuals seem old-fashioned.

"some slides and videos look very old fashioned..."

"The Course is ok, but not worth to pay for... you can find the same information on the internet for free..."

Six Sigma section is an overview, lacks depth.

"The course is good but Six Sigma needs to be more in depth for this is one of the most important section..."

"It would have been great if it covered more Six Sigma concepts and its applicability across different industries."

"it covers only the very basic knowledge on lean manufacturing and six sigma concepts..."

Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Lean Manufacturing A-Z: Operations Management & Six Sigma with these activities:

Review Basic Statistics Concepts

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Refresh your understanding of basic statistical concepts to better grasp the Six Sigma principles covered in the course.

Browse courses on Statistical Process Control

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Review descriptive statistics.
Study probability distributions.
Practice hypothesis testing.

Read 'The Goal' by Eliyahu M. Goldratt

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Understand the Theory of Constraints through a narrative that highlights the importance of identifying and eliminating bottlenecks.

View The Goal: A Process of Ongoing Improvement -... on Amazon

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Read the book, taking notes on key concepts.
Reflect on how the concepts apply to different industries.

Value Stream Mapping Project

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Apply Value Stream Mapping (VSM) to a real-world process to identify waste and opportunities for improvement.

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Select a process to map.
Create a current state VSM.
Identify areas of waste.
Develop a future state VSM.
Implement changes and monitor results.

Four other activities

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Show all seven activities

5S Audit Practice

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Conduct mock 5S audits in a workspace to reinforce understanding of the 5S methodology and improve observation skills.

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Define the audit criteria.
Conduct the audit.
Identify areas for improvement.
Develop an action plan.

Create a 'TIMWOODS' infographic

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Design an infographic that visually explains the 8 wastes of Lean (TIMWOODS) to reinforce understanding and aid in communication.

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Research the 8 wastes of Lean.
Design the infographic layout.
Create visuals to represent each waste.
Add descriptions and examples.
Share the infographic with others.

Read 'Lean Thinking' by James P. Womack and Daniel T. Jones

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Deepen your understanding of Lean principles and their application across various industries.

View Lean Thinking on Amazon

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Read the book, highlighting key takeaways.
Reflect on how Lean Thinking can be applied in your workplace.

Explore Six Sigma DMAIC Tutorials

Show steps

Follow online tutorials that walk through the DMAIC (Define, Measure, Analyze, Improve, Control) process to solidify your understanding of Six Sigma.

Show steps

Find DMAIC tutorials online.
Follow the steps in the tutorials.
Apply the DMAIC process to a sample problem.

Career center

Learners who complete Lean Manufacturing A-Z: Operations Management & Six Sigma will develop knowledge and skills that may be useful to these careers:

Plant Manager

A Plant Manager oversees all operations within a manufacturing plant, ensuring efficient production and adherence to safety standards. This course on Lean Manufacturing and Six Sigma is useful for a Plant Manager, providing a comprehensive understanding of operational excellence. The course's coverage of Lean principles, Six Sigma methodologies, and Kaizen techniques are directly relevant to plant management. A Plant Manager learns how to optimize production processes, reduce waste, and improve overall plant efficiency. The modules on inventory management, quality control, and total productive maintenance (TPM) are particularly valuable. This course equips a Plant Manager to improve plant performance, reduce costs, and ensure a safe and productive work environment.

See salaries and explore the career path for Plant Manager

Operations Manager

An Operations Manager is responsible for overseeing the daily activities involved in producing goods or services. This course on Lean Manufacturing and Six Sigma is valuable for an Operations Manager because it helps build skills needed to streamline processes, reduce waste, and improve overall efficiency. The course covers essential tools and methodologies of Lean, Six Sigma, and Kaizen, all of which contribute to enhanced business operations. By mastering concepts such as value stream mapping, waste reduction, and quality management, the Operations Manager learns to optimize processes, improve profitability, and increase customer satisfaction. The modules on inventory management, scheduling, and production planning are particularly relevant, as these are areas where an Operations Manager can implement changes. The course equips an Operations Manager with practical knowledge to drive significant improvements in operational performance.

See salaries and explore the career path for Operations Manager

Operations Director

The Operations Director is responsible for overseeing and directing the operational activities of an organization to ensure efficiency and effectiveness. This course on Lean Manufacturing and Six Sigma is valuable for an Operations Director, providing a comprehensive understanding of Lean methodologies and Six Sigma principles. The course's curriculum on Lean fundamentals, value stream mapping, and waste reduction techniques are directly applicable to optimizing operational processes. An Operations Director can use the knowledge gained from the course to improve efficiency, reduce costs, and enhance overall operational performance. The content on scheduling, quality management, and continuous improvement equips them to drive significant improvements across the organization.

See salaries and explore the career path for Operations Director

Continuous Improvement Manager

The Continuous Improvement Manager spearheads initiatives to enhance organizational performance through process optimization and waste reduction. For a aspiring Continuous Improvement Manager, this Lean Manufacturing and Six Sigma course provides a strong foundation in the methodologies crucial for their role. The course's focus on Lean fundamentals, Six Sigma principles, and Kaizen techniques directly aligns with the responsibilities such as a manager, planner, consultant, analyst, engineer, or supervisor. The course material on value stream mapping, the eight wastes of Lean, and the PDCA improvement cycle are critical for identifying and addressing areas for improvement. Furthermore, the knowledge gained from the course equips the Continuous Improvement Manager to lead change, improve processes, and boost business performance effectively.

See salaries and explore the career path for Continuous Improvement Manager

Production Supervisor

A Production Supervisor oversees and coordinates the activities of production workers to ensure efficient and timely manufacturing processes. This course on Lean Manufacturing and Six Sigma is extremely relevant for a Production Supervisor, providing them with the knowledge to optimize production processes and improve team performance. The course's coverage of Lean principles, 5S methodology, and standard work are directly applicable to this role. Mastering concepts like waste elimination, visual management, and process standardization will lead to a Production Supervisor to drive continuous improvement and enhance productivity. This course provides practical tools for leading production teams effectively.

See salaries and explore the career path for Production Supervisor

Process Engineer

A Process Engineer designs, develops, and optimizes industrial processes to maximize efficiency and minimize waste. This course on Lean Manufacturing and Six Sigma is extremely beneficial for Process Engineers, providing them with the tools and knowledge to enhance process design and operational efficiency. The course's coverage of Lean principles, Six Sigma methodologies, and Kaizen techniques are directly applicable to this role. Process Engineers benefit from the modules on value stream mapping, 5S methodology, and statistical process control. Mastering these concepts allows a Process Engineer to improve process flow, reduce variation, and implement mistake-proofing measures. The course equips a Process Engineer to drive continuous improvement and optimize manufacturing and service processes.

See salaries and explore the career path for Process Engineer

Quality Engineer

A Quality Engineer focuses on ensuring that products or services meet quality standards and customer expectations through process improvement and quality control. This course on Lean Manufacturing and Six Sigma gives a Quality Engineer tools to enhance their work. The course's concentration on Six Sigma principles, statistical process control, and root cause analysis are essential for maintaining and improving product quality. A Quality Engineer benefits from modules on reducing variation, implementing mistake-proofing measures, and total productive maintenance. The insights gained from the course equip a Quality Engineer to implement robust quality management systems, reduce defects, and ensure customer satisfaction.

See salaries and explore the career path for Quality Engineer

Supply Chain Manager

The Supply Chain Manager oversees the flow of goods, information, and resources from suppliers to customers. This course on Lean Manufacturing and Six Sigma can greatly assist a Supply Chain Manager in optimizing supply chain operations and improving efficiency. The course's curriculum on Lean principles, inventory management, and demand management are directly relevant to supply chain optimization. A Supply Chain Manager learns how to reduce waste, improve flow, and minimize inventory costs. The course's teaching on scheduling, production planning, and pull systems are particularly valuable for aligning supply with demand and reducing lead times. This course prepares a Supply Chain Manager to enhance supply chain performance and improve customer satisfaction.

See salaries and explore the career path for Supply Chain Manager

Inventory Manager

An Inventory Manager oversees the inventory levels and ensures efficient stock management to meet demand while minimizing costs. This course on Lean Manufacturing and Six Sigma is extremely useful for a Inventory Manager. The course's modules on inventory management, waste reduction, and flow optimization are particularly relevant. An Inventory Manager learns how to apply Lean principles to reduce excess inventory, improve inventory accuracy, and streamline the flow of materials. Furthermore, they learn techniques such as kanban and pull systems. This course equips an Inventory Manager to enhance inventory control, reduce holding costs, and improve overall supply chain efficiency.

See salaries and explore the career path for Inventory Manager

Quality Assurance Manager

A Quality Assurance Manager ensures that products or services meet specific quality standards and customer expectations. For a Quality Assurance Manager, this course on Lean Manufacturing and Six Sigma offers valuable insights into quality improvement methodologies and techniques. The course covers Six Sigma principles, statistical process control, and root cause analysis, all of which are essential for maintaining and improving product quality. A Quality Assurance Manager benefits from the modules on reducing variation, mistake-proofing (Poka-Yoke), and total productive maintenance (TPM). The course prepares a Quality Assurance Manager to implement quality management systems, reduce defects, and ensure customer satisfaction. This course provides knowledge to excel in ensuring quality standards are met consistently.

See salaries and explore the career path for Quality Assurance Manager

Manufacturing Engineer

A Manufacturing Engineer designs, implements, and maintains manufacturing processes to ensure efficient and cost-effective production. This course on Lean Manufacturing and Six Sigma provides Manufacturing Engineers with the skills and knowledge to optimize manufacturing operations and improve productivity. The course's curriculum on Lean principles, value stream mapping, and 5S methodology are directly applicable to this role. Manufacturing Engineers learn how to eliminate waste, improve workflow, and reduce cycle times. The modules on SMED (single-minute exchange of die), visual management, and standard work are particularly useful for enhancing manufacturing efficiency. This course prepares a Manufacturing Engineer to drive continuous improvement and optimize manufacturing processes.

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Supply Chain Analyst

A Supply Chain Analyst analyzes supply chain data to identify areas for improvement and optimize supply chain performance. This course on Lean Manufacturing and Six Sigma helps a Supply Chain Analyst by providing the foundation for identifying and eliminating inefficiencies. The course emphasizes Lean fundamentals, inventory management, and process mapping. The techniques allow an analyst to assess and streamline the flow of goods and information. A Supply Chain Analyst benefits from the course's modules on waste reduction, process improvement, and demand management. With these skills, a Supply Chain Analyst can drive improvements in supply chain efficiency, reduce costs, and enhance overall supply chain performance.

See salaries and explore the career path for Supply Chain Analyst

Business Analyst

A Business Analyst identifies business needs and determines solutions to business problems. This course on Lean Manufacturing and Six Sigma may be quite helpful for a Business Analyst, providing them with a framework for analyzing and improving business processes. The course's coverage of Lean principles, value stream mapping, and waste reduction techniques are relevant to identifying inefficiencies and recommending improvements. A Business Analyst benefits from the modules on process mapping, data analysis, and root cause analysis. The course prepares a Business Analyst to improve business processes, reduce costs, and increase efficiency. Armed with these skills, a Business Analyst will be able to analyze business processes that involve manufacturing.

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Management Consultant

A Management Consultant advises organizations on how to improve their performance and efficiency. This course on Lean Manufacturing and Six Sigma may provide you with a valuable toolkit for assessing and optimizing business operations. The course's coverage of Lean principles, Six Sigma methodologies, and Kaizen techniques is applicable to a wide range of industries and business functions. A Management Consultant will find the modules on value stream mapping, process improvement, and change management particularly useful. The course prepares a Management Consultant to improve business performance, reduce waste, and increase profitability. This course may help a Management Consultant drive improvements in various operational areas.

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Project Manager

A Project Manager plans, executes, and closes projects, ensuring they are completed on time and within budget. This course on Lean Manufacturing and Six Sigma may prove useful for a Project Manager, providing them with methodologies for improving project efficiency and reducing waste. The course’s curriculum on Lean principles, process improvement, and scheduling are transferable to project management. A Project Manager will learn how to streamline project workflows, eliminate bottlenecks, and improve resource utilization. Modules on value stream mapping will be useful within the context of project deliverables. The course will equip a Project Manager to deliver projects more efficiently and effectively.

See salaries and explore the career path for Project Manager

Lean Manufacturing A-Z

Operations Management & Six Sigma

What's inside

Learning objectives

Syllabus

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Reviews summary

Foundational lean & six sigma

Activities

Career center

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