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  • Provider edX
  • Cost Free Online Course (Audit)
  • Session Self Paced
  • Language English
  • Certificate $99 Certificate Available
  • Effort 3-4 hours a week
  • Start Date
  • Duration 6 weeks long
  • Learn more about MOOCs

Taken this course? Share your experience with other students. Write review

Overview

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 key organisation and managerial approaches that are used in Lean.

You will learn how to analyse process flows in order to establish process capacity and identify the process bottleneck. You will then calculate resource utilisation 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.

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 for edX's Lean Production
4.9 Based on 67 reviews

  • 5 stars 94%
  • 4 stars 6%
  • 3 star 0%
  • 2 star 0%
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  • 1
Vlad I
5.0 a year ago
by Vlad completed this course, spending 4 hours a week on it and found the course difficulty to be medium.
I am ashamed to admit that coming into this course I had no idea what Lean Production was and was only taking the course as it was part of the Six Sigma Yellow Belt certification program that I was interested in obtaining. I could not be happier with myself for taking this course because the information I obtained there has helped me immensely in my work and home life.

The material was presented in an easy-to-understand and logical way, with concepts that were learned earlier on in the course becoming applicable again in later sections. Lecture slides were provided, which was nic…
Was this review helpful to you? Yes
Anonymous
5.0 a month ago
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 which most people fail to do in lectures. Some students do not give her enough credit for how she sets up her lectures and her practice question are very good preparations for her quizzes/homework assignments. I have seen a lot of professors in my lifetime none of them of them were ever actually good, very intelligent people that mostl…
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Sergey T
5.0 a year ago
Sergey completed this course, spending 4 hours a week on it and found the course difficulty to be medium.
In short this course is great! I would have to choose one word to describe this course it would be “efficient”. Detailed review. The lectures cover all important Lean topics. Typical lecture is about 10-15min long and covers one topic or gives an overview. This means it is possible to distribute course material over the week or go through the material on a weekend. If you look for more information useful links, books etc are provided. You can use discussion board to ask questions or to discuss a topic in general. Discussion board provided many real-life and first-hand experience. Handouts and …
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Anonymous
5.0 a year ago
Anonymous completed this course.
The course was excellent from every aspect:


Topics are split up in 6 sessions/weeks that accommodated a full time employee to still manage a good work-life balance.

The analytical process is explained in easy words, so one must not be afraid of not understanding the context, if not a native english speaker.

The teachers are easy to reach out to and answered questions right away. (Thank you so much).

The course is well structured with easy understandable examples the students can do their calculations on.

I can fully recommen…
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Christian K
5.0 a year ago
Christian completed this course.
At the beginning I took this course just to show current or future employers my experience in this topic and didn't expect anything so new for me as it's my filed of work as a manager in continuous improvement. But as the course commenced, I have learnt more and more details that I could already implement in day to day work. I really enjoyed this course and it's sure that i will enroll in the additional ones in this TUMx professional program. Prof. Holly Ott and her team managed to develop a great MOOC that is fun and horizon expanding. Prof. Ott is a frequent follower (and responder) of forum discussions which encourages everyone to exchange experiences. Not to forget the emails you get during the course with great pointers to real world problems. All in all, I can recommend this MOOC a lot to anyone who is even remote interested in lean and production management.
Was this review helpful to you? Yes
Murali K
5.0 a year ago
Murali completed this course, spending 4 hours a week on it and found the course difficulty to be medium.
One of the best MOOC on Lean production that you can find online. Whether you are a novice or an expert, this course gives you the concise content that is required to understand lean.

The course is well structured, perfectly presented with case studies, examples, math problems, discussion forum, guest lectures given by prominent faculty members from reputed universities around the world. The best things about the course are the faculty members & the participants, who bring in rich diverse experience either educationally or professionally or both.

I would recommend this course as well as other courses that are part of TUM's Professional Certificate Program to those who want to learn or brush up their skills in six sigma and lean.

Thank you very much Mr.Martin, Mrs. Holly, Mr. Reiner, Mr.Zubair and the entire support team. Take a bow!
Was this review helpful to you? Yes
Lilian B
5.0 2 months ago
Lilian completed this course, spending 10 hours a week on it and found the course difficulty to be medium.
This course is a great opportunity to learn important quality matters.

The course is very well structured, the complexity is just fine for upper-beginner level, the topics are explained in good details. You have the opportunity to replay video and recheck the material before advancing, the practical exercises are very useful and you may check the explanations and clarifications (after you answer).

The instructors give good examples to show how the theory can be used. The course trainers (Prof. Holly Ott, Prof. Martin Grunow) are extraordinary.

I have completed all 3 courses. All three courses in the series are of great price.

This course is of real help in my projects. Recommend this course to anyone who want to start their journey into Six Sigma and Lean world.

I feel proud to be a part of this program.

Thank you TUM!
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Olga F
5.0 a year ago
Olga completed this course, spending 4 hours a week on it and found the course difficulty to be medium.
I am a Materials Engineer with more than 10 year background on quality, design and manufacturing of rotor blades for the wind industry. I took this course to improve my knowledge and apply the Six Sigma methodology to my daily work: office and factory enviroments. Moreover, a lot of big companies are requiring employees with at least GB and with you (course team) and edx is a great opportunity to obtain. You are more cost-effective and the explanations and papers are the best.

I did enjoy taking the lessons, very descriptive, completed, and clear with all materials well-prepared. I have now a good basis to start working with this methodology. Thank you very much for this course of Lean and for the Programme of Six Sigma!!.

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Anonymous
5.0 2 months ago
Anonymous completed this course.
The production quality of this course is high. The content is well presented, and supplemented with exercises and case studies.

Among the learned concepts were the product-process matrix, the 7 wastes, resource utilization, overall equipment effectiveness, workplace visualization, 5S, push/pull system, kanban, the Toyota way, error proofing, and more.

Personally, I'm not directly involved in production planning. Nonetheless (or especially because), the course was very instructional as it showed how certain misconceptions may contribute to large capacity losses down th…
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Umang M
5.0 6 months ago
Umang completed this course, spending 18 hours a week on it and found the course difficulty to be medium.
The course content is very much helpful and informative. The course really helps to gain insight into the lean production and six sigma. The concepts are very much latest and related with industry.

The course has helped me a lot for securing the internship at Schaeffler Company. The material has proved to be very much useful with the project I am working in Schaeffler.

The instructor (Holly) seems to be genuinely excited about the subject she is teaching which makes the lectures interesting and helps to keep you motivated.

Was this review helpful to you? Yes
Anonymous
5.0 2 months ago
Anonymous completed this course.
I've been in the business world about 30 years now and I've seen many changes. I first learned about the Toyota Way through watching Harley-Davidson almost die and then be resurrected through taking manufacturing lessons from the Japanese motorcycle builders. Of course, I didn't recognize the significance at the time - it just seemed to me that Honda taught HD a few things and HD fixed itself using what it learned. Many years later I was introduced to Six Sigma via an acquisition. Suddenly, our small company had what seemed like 50 VP's of something or other running around trying to measure ev…
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Grzegorz W
5.0 6 months ago
Grzegorz completed this course, spending 3 hours a week on it and found the course difficulty to be medium.
Grzegorz completed this course, spending 3 hours a week on it and found the course difficulty to be medium.

I find this course and the Six Sigma and Lean: Quantitative Tools for Quality and Productivity program as one of the best I've ever participated in. I highly recommend to anyone who would like to start the Lean Six Sigma journey. Once program completed, the Green Belt certyficate is in hand coverage.

Thank you Holly Claudia Ott, Technical University Munich and edX.

#leansixsigma #leanmanufacturing #sixsigma
Was this review helpful to you? Yes
Pavan K
5.0 a year ago
by Pavan completed this course, spending 3 hours a week on it and found the course difficulty to be medium.
The course content is very well designed. The concepts taught by Professor and the examples she provides are very appropriate and can be implemented across various disciplines.

The response of the team to the difficulties during course are very well and timely addressed.

All in all this is one of the excellent course being provided by a reputed university, and handled very well by an experienced Professor and her team.
Was this review helpful to you? Yes
Anonymous
5.0 a year ago
Anonymous completed this course.
This was a well organized, insightful and practical course on lean. It was a perfect balance of lectures, case studies and homework which continually transformed concepts into reality. The instructors were excellent and experts in the field. It gave me a very solid grounding in lean production and associated methods and I would recommend it to anyone with interest in the area and working on six sigma.

Currently enjoying the other parts of the program and finding it a great basis for designing processes.
Was this review helpful to you? Yes
Anonymous
5.0 a year ago
Anonymous completed this course.
This is without doubt, one of the best course about six sigma, no just in EDX website,but in our quality world. I think the best thing in our lives in access a good education, even thoug if we don´t have enough Money to do it, and TUM gave me that opportunity. I live in Brazil, in a poor countryside and cause of it I´m Always trying to get a good education, to improve myself and achieve my carreer gols. This course help me me a lot, with the best teachers and good material. Thank you TUM.
Was this review helpful to you? Yes
Anonymous
5.0 a year ago
Anonymous completed this course.
The course is excellent! I didn't know anything about Lean before starting the course, and I have learned a lot! The course content was taught in a great order and in a very didact way, allowing a gradual development without being tiring. The experiences shared among the classmates and teachers were very important and helpful for a better understanding of the content.

Thank you all! It was a great first experience with edX course for me!
Was this review helpful to you? Yes
Anonymous
5.0 4 weeks ago
Anonymous completed this course.
My name is Fosu Brempong from Ghana. I must say each course under Six Sigma program is superb and educative. In all the three courses, I am so engrossed and glued to lean production. The new ideas and skills I have gained from this course is awesome. I am an engineer and I’m also into business improvement and operation management. And for that matter, this course has empowered me to apply all tools, skills, methods, techniques and knowledge in Lean Production to efficiently, effectively, economically and successfully handle any construction, manufacturing and production project or program that…
Was this review helpful to you? Yes
Anonymous
5.0 2 months ago
Anonymous completed this course.
This course is just amazing. Excellent practical knowledge of lean principles of how they get implemented has been taught in this program. I have taken this course on edX, and the course instructor especially Miss Holly Ott is very much responsive. This course not only helped my in my capacity analysis project but also elevated my interest for learning advanced operations management techniques.
Was this review helpful to you? Yes
Yadhunath K
5.0 a year ago
Yadhunath completed this course, spending 5 hours a week on it and found the course difficulty to be medium.
Prof Holly,

I am happy to inform you that I have now passed the Green Belt certification of ASQ . Waiting for the certificate to arrive.

Even though my experience span over 27 yrs in the industry, I could not formally get educated in the Six Sigma BOK. Your course helped me a lot in this regard. Many thanks to you , Prof Zubair and to your entire team of this course.

Thank You once again
Was this review helpful to you? Yes
Anonymous
5.0 2 months ago
Anonymous completed this course.
This is the third/last course in the TUM Yellow Belt Track. The program would not be complete without this particular course. At the time, I was working at the Boeing factory in Everett, USA. My role was totally unrelated to Six Sigma or Lean Production. This course helped me see the implementation of Lean Production in a factory setting and how everything is interconnected.
Was this review helpful to you? Yes
  • 1

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