Lean Production from edX

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 Green Belt level. The material is based on the American Society for 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.

What's inside

Learning objectives

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.

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.

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 help fool-proof our processes and learn how to structure and run a Kaizen Blitzto 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.

Good to know

Know what's good

, what to watch for

, and possible dealbreakers

Taught by recognized experts in Lean, Martin Grunow and Holly Ott

Intermediate-level, expects students are familiar with Lean concepts and tools

Covers key Lean principles and tools, including Just-in-Time, Kaizen, and 5S

In-depth study of process analysis, which is essential for Lean implementation

Provides a strong foundation for Lean Six Sigma Green Belt certification

Suitable for professionals in manufacturing, operations, and supply chain management

Reviews summary

Top-rated lean production course

This well-received course on Lean Production offers a comprehensive overview of the topic, suitable for both beginners and experienced professionals. With a focus on practical applications, the course provides valuable insights and skills that can be immediately implemented in the workplace or daily life.

Variety of learning materials (lectures, case studies).

"Typical lecture is about 10-15min long and covers one topic or gives an overview..."

"Handouts and videos can be downloaded..."

Easy-to-understand explanations and examples.

"Theory in this course is explained well..."

"The explanations are clear..."

Expert instructors with real-world experience.

"The instructors were excellent and experts in the field."

"Prof Holly Ott and her team managed to develop a great MOOC..."

Well-designed and informative content.

"The course is well designed..."

"The course content is very well designed..."

Applicable to various industries and daily life.

"The concepts taught by Professor and the examples she provides are very appropriate and can be implemented across various disciplines."

"Most of the concepts and techniques learned can be applied to any kind of industries and even daily life..."

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 Production with these activities:

Read and Summarize Book on Lean Production

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Understand the foundational principles and practices of Lean Production to lay a strong knowledge base for the course.

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Read the book and take notes on key concepts.
Write a summary of the book, highlighting the main ideas and how they relate to Lean Management.

Explore Online Resources on Lean Management

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Expand knowledge and understanding of Lean principles and practices by exploring online resources.

Browse courses on Lean Management

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Search for online tutorials, articles, and videos on Lean Management.
Review the materials and take notes on key concepts.
Test your understanding by completing practice exercises or quizzes.

Design a Process Flow Map for a Lean Manufacturing System

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Apply the principles of Lean to optimize a manufacturing process by identifying and eliminating waste.

Browse courses on Value Stream Mapping

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Identify a manufacturing process to map.
Collect data on the existing process, including cycle time, waste, and bottlenecks.
Create a visual representation of the process flow.
Identify opportunities for improvement based on Lean principles.
Design a new process flow map that includes the improvements.

Four other activities

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Participate in Lean Six Sigma Study Group

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Engage with peers and experts to discuss and solve Lean Six Sigma-related problems and challenges, enhancing understanding and problem-solving skills.

Browse courses on Lean Six Sigma

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Join a Lean Six Sigma study group.
Participate in group discussions and activities.
Collaborate on problem-solving projects.

Calculate Lean Metrics for a Manufacturing Process

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Develop proficiency in calculating key Lean metrics to evaluate the performance of a manufacturing process.

Browse courses on Performance Measurement

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Identify the relevant Lean metrics for the process.
Collect data on the process.
Calculate the Lean metrics using the collected data.
Analyze the results and identify areas for improvement.

Develop a Lean Training Plan for Your Organization

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Enhance the knowledge and skills of your team by creating a comprehensive Lean training plan tailored to your organization's needs.

Browse courses on Process Improvement

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Assess the current knowledge and skills level of your team.
Identify the specific Lean concepts and techniques that need to be covered in the training.
Develop a training curriculum that includes interactive exercises, case studies, and hands-on simulations.
Deliver the training and provide ongoing support to ensure effective implementation.

Implement a Lean Improvement Project in Your Workplace

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Apply Lean principles and tools in a real-world setting to enhance process efficiency and effectiveness.

Browse courses on Process Improvement

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Identify a suitable Lean improvement project within your workplace.
Form a team and define the project scope.
Analyze the existing process and identify areas for improvement.
Implement Lean tools and techniques to improve the process.
Monitor and evaluate the results of the improvement project.

Career center

Learners who complete Lean Production will develop knowledge and skills that may be useful to these careers:

Lean Manufacturing Consultant

A Lean Manufacturing Consultant helps businesses implement Lean Production principles. This includes identifying and eliminating waste, improving flow, and maintaining quality. This course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you the tools and techniques you need to be successful as a Lean Manufacturing Consultant.

See salaries and explore the career path for Lean Manufacturing Consultant

Six Sigma Black Belt

A Six Sigma Black Belt is a professional who is certified in the Six Sigma methodology. Six Sigma is a data-driven approach to improving processes and reducing waste. This course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you the tools and techniques you need to be successful as a Six Sigma Black Belt.

See salaries and explore the career path for Six Sigma Black Belt

Process Engineer

A Process Engineer is responsible for designing and improving processes. This includes identifying and eliminating waste, improving flow, and maintaining quality. This course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you the tools and techniques you need to be successful as a Process Engineer.

See salaries and explore the career path for Process Engineer

Continuous Improvement Manager

A Continuous Improvement Manager is responsible for leading and managing continuous improvement initiatives. This includes identifying and eliminating waste, improving flow, and maintaining quality. This course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you the tools and techniques you need to be successful as a Continuous Improvement Manager.

See salaries and explore the career path for Continuous Improvement Manager

Industrial Engineer

An Industrial Engineer is responsible for designing and improving industrial processes. This includes identifying and eliminating waste, improving flow, and maintaining quality. This course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you the tools and techniques you need to be successful as an Industrial Engineer.

See salaries and explore the career path for Industrial Engineer

Operations Manager

An Operations Manager is responsible for overseeing the day-to-day operations of a business. This includes managing staff, setting up processes, and ensuring that the business is running smoothly. This course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you how to identify and eliminate waste, improve flow, and maintain quality. This knowledge will be essential for success as an Operations Manager.

See salaries and explore the career path for Operations Manager

Manufacturing Engineer

A Manufacturing Engineer is responsible for designing and improving manufacturing processes. This includes identifying and eliminating waste, improving flow, and maintaining quality. This course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you the tools and techniques you need to be successful as a Manufacturing Engineer.

See salaries and explore the career path for Manufacturing Engineer

Production Manager

A Production Manager is responsible for overseeing all aspects of production. This includes planning and scheduling production, ensuring quality control, and managing inventory. Taking this course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you how to identify and eliminate waste, improve flow, and maintain quality. This knowledge will be essential for success as a Production Manager.

See salaries and explore the career path for Production Manager

Quality Engineer

A Quality Engineer is responsible for ensuring that products and services meet quality standards. This includes developing and implementing quality control procedures, and working with other departments to improve quality. This course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you the tools and techniques you need to be successful as a Quality Engineer.

See salaries and explore the career path for Quality Engineer

Quality Assurance Manager

A Quality Assurance Manager is responsible for ensuring that products and services meet quality standards. This includes developing and implementing quality control procedures, and working with other departments to improve quality. This course can help you build a foundation in Lean Production, which is a valuable methodology for improving efficiency and reducing waste. The course will teach you the tools and techniques you need to be successful as a Quality Assurance Manager.

See salaries and explore the career path for Quality Assurance Manager

Supply Chain Manager

A Supply Chain Manager is responsible for managing the flow of goods and services from suppliers to customers. This includes planning, organizing, and controlling the supply chain. This course may be useful for Supply Chain Managers who are looking to improve their skills in process improvement. The course will teach you how to identify and eliminate waste, improve flow, and maintain quality. This knowledge can be applied to any supply chain, regardless of industry.

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Operations Research Analyst

An Operations Research Analyst is responsible for using mathematical and analytical methods to solve business problems. This includes identifying and eliminating waste, improving flow, and maintaining quality. This course may be useful for Operations Research Analysts who are looking to improve their skills in process improvement. The course will teach you how to identify and eliminate waste, improve flow, and maintain quality. This knowledge can be applied to any business problem, regardless of industry.

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Logistics Manager

A Logistics Manager is responsible for planning, organizing, and controlling the movement of goods and services. This includes managing transportation, warehousing, and inventory. This course may be useful for Logistics Managers who are looking to improve their skills in process improvement. The course will teach you how to identify and eliminate waste, improve flow, and maintain quality. This knowledge can be applied to any logistics operation, regardless of industry.

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Project Manager

A Project Manager is responsible for planning, executing, and closing projects. This includes managing project scope, schedule, and budget. This course may be useful for Project Managers who are looking to improve their skills in process improvement. The course will teach you how to identify and eliminate waste, improve flow, and maintain quality. This knowledge can be applied to any project, regardless of industry.

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Business Analyst

A Business Analyst is responsible for analyzing business processes and identifying opportunities for improvement. This includes identifying and eliminating waste, improving flow, and maintaining quality. This course may be useful for Business Analysts who are looking to improve their skills in process improvement. The course will teach you how to identify and eliminate waste, improve flow, and maintain quality. This knowledge can be applied to any business, regardless of industry.

See salaries and explore the career path for Business Analyst