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Lean Production

Technische Universität München (Technical University of Munich) via edX

Overview

  • The current course run ends on June 30, 2021. If you think you won't have enough time to finish, you can enroll in the run starting on May 01, 2021 and ending on June 30, 2022 *

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.

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.

Taught by

Martin Grunow and Holly Ott

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Reviews

4.9 rating, based on 677 reviews

Start your review of Lean Production

  • Hello, my name is Christian Salinas, I am an industrial engineering student and I am from El Salvador. I really liked this course a lot, it has a lot of topics that help you see things in different ways. I would like to mention a little about what most catches my attention, I think it is very important to keep 7 Wastes in mind in every opportunity that comes our way and thus improve productivity, thanks to the classes it is easy to remember them. 5S is also very important as it is of great help in any organization and even in ourselves with our styles of life. Finally, the Visual Management part I think is something that should call everyone's attention because it can be immediately put into practice and helps us to use our imagination.
  • Aziz Senzia completed this course, spending 5 hours a week on it and found the course difficulty to be medium.

    What an experience! First of all, I would like to thank all lecturers and guest lecturers for this course (Lean Production) for their valuable materials. They all made this course possible for their vast knowledge and experience in the area(s) they...
  • Vishnu A Nair

    India

    Quality Manager( E-commerce)

    I learned how to look into problems and solve them in a lean production way. A big thanks to the course and lecturers.

    5 wastes in production. This was a major concern in my factory. Now I can study each waste and solve it gradually. Also, 5s which was implemented was not sustained. Now, 5s is active :)

  • Anubha Asthana completed this course.

    Hi, I am Anubha Asthana from India. I am currently working for Globallogic Technologies Pvt. Ltd. as Quality Analyst on the project of Google. The three specific things I learned in the course were: 1. Ample amount of information and learning. For a...
  • I finally completed this series. it took me about one year of part-time studying.. before enrolling to the TUM Lean Six Sigma bundle I searched the internet for almost every training providers, but I never found anything that matches the content, volume, practical application, and effectiveness of this course!
    I would like to thank Dr. Holly, Dr. Martin, Dr. Reiner, Mr. Zubair, and the rest of the team for their great efforts and dedication towards making this course. It is an affordable course yet it is priceless considering the learning outcomes!
  • My name is Rony Tabari and I am from Indonesia, I am currently undertaking a role as an Operations Improvement Advisor for Phu Bia Mining (PBM) with operations in Laos as one of the producing assets for PanAust in South East Asia. Again, first of all,...
  • Profile image for Pablo Rojas
    Pablo Rojas
    1
    Muy completo y bien detallado! Había escuchado del término Lean pero rara vez lo había reconocido en el día-día. El curso me parece bastante completo: desde el aspecto conceptual, ejemplos, cálculos y datos complementarios. Se hace bastante llevadero...
  • Anonymous

    Anonymous completed this course.

    The professor Holly Ott understands what a S.M.A.R.T (specific measurable attainable realistic time) quality objective actually is for a each of her lectures. Furthermore she follows the 3E( FEMA Reinforcing the perception of fair treatment 3E) of communication...
  • Anonymous
    The course was particularly useful in the compression of the whole dynamics of a production process, analysing in detail each phase from raw materials to the finished goods. I found it particularly interesting to learn the JIT(Just-In-Time) concept, with...
  • Anonymous
    Dear reader, Im working in a sliced meat company. I understand better the calculations behind certain data we gather in the factory. For example the overall effectiveness. Its makes me curious to analyse the data in more detail. Furthermore I got inspired...
  • Anonymous
    Have completed the Lean Production courses and found it very practical and useful. This course is easy to access, well structured and guide learner step by step to gain knowledge and terminology. There is always detail explanation and example to illustrate...
  • Kun Hu
    1
    Name: Kun Hu

    Location: Munich, Germany

    Type of Company: Chemical Production

    Highlights:

    - comprehensive overview of the Lean Production concepts

    - combination with guest lectures with practical industry experience

    - clear and good strctured learning material

    - practical test to strengthen learning effort

    - applicable for daily business and projects

    The lean production shared much thinking methods and philosophy of how you treat a problem, analyze the root cause and develops solution to solve it, highly appreciate to get refreshed with the shared knowledge here.

  • Anonymous
    The course followed a clear and logic structure. It helped me develop a skillset in lean production and at the same time increased my understanding of the scope in real world applications. The graded tasks support the learnings and ensure definite understanding as goal-oriented parts of the whole course. The lecturers perfectly supported the course showing deep understanding and advanced knowledge in the area, while also integrating interactive tasks that ensured deeper involvement with the tasks at hand.
    GCdaniel
  • Anonymous

    Anonymous completed this course.

    Hello ! I am Nuruzzaman Faruqui from Dhaka, Banglades. I am an Electrical Engineer and working in Banglalink Digital Communications Ltd with the Technical Project Team of my company . I have to work & perform with different project all over the year. I...
  • Abdel Kader Traore
    2

    Abdel Kader Traore completed this course.

    The course is really amazing. As a fresh enginner in food science working at one the leading manufacturers of chocolate, I already knew about lean production and several tools associated with it (VSM, kanban, SMED, OEE, 5S etc.). But I was not able...
  • Anonymous
    It's concise and highly beneficial training course with extensive direct to the point presentation. Practice tutorial in each section helps uncover non understood areas and strengthening the knowledge gained.

    I do suggest this course to all quality professionals who aim to have strong and distinguished understanding of Lean & Six Sigma.
  • Anonymous
    El programa es muy completo, me ha ayudado a integrar no solo conocimiento técnico, sino a reconocer parte de una cultura de trabajo que no solo impacta resultados a nivel laboral, sino también personal.

    Pues son prácticas totalmente aplicables en la cotidianidad.
  • Anonymous
    Ibrahim khalid

    I enjoyed this course

    Very helpful for beginners

    But the content is not detailed and there is no real case scenarios also quality of some videos was not good

    Content needs to be more detailed with implementation of tools on real scenarios
  • Anonymous
    One of the best course Lean Production over the internet by TUM in collaboration with edX.

    Best professor, guest lecture, and lots of practice questions and homework sessions.

    Enjoyed the overall journey.
  • Profile image for Yogesh Raju Subramanya
    Yogesh Raju Subramanya
    I am Yogesh, a Master Science student in Germany and a professional Mechanical Engineer experienced in design, production, and material engineering in aerospace and automotive sectors. In my professional experience, I had already worked with the implementation...

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