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edX

Lean Production

Technische Universität München (Technical University of Munich) via edX

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 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

Reviews

4.9 rating, based on 801 Class Central reviews

Start your review of Lean Production

  • 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...
  • 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.
  • 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...
  • 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 :)

  • 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,...
  • Anonymous
    This is the end of an adventure.
    After having spent more dozens of hours learning the basics of Six Sigma with QPLS1x and QPLS2x, this final session dedicated to Lean Production was very useful and relevant, in regards with what I've learned.
    I have particularly appreciated the reminder of Toyota Production System and deep dive into its inheritance.
    5S, Kazan, Heijunka, Jidoka, etc. These have no more secrets for me.
  • Profile image for Jean Paul Nkurikiyintwar
    Jean Paul Nkurikiyintwar
    This course was more helpful for me as I got much additional knowledge on Lean production.

    I was able to know the 7 types of waste in the production cycle (Transportation, Motion, Inventory, waiting, over-processing, overproduction, and defect).

    As someone who deals with the inventory, I knew how I can prevent defects as well as support the production in ensuring that we are providing good quality materials.
  • Anonymous
    Hello! My name is Tatiana Polishchuk. I am a student of the Czech Technical University in Prague. I am a second year student in Economics and Management(Bachelor degree). The course was online, nevertheless there was a complete immersion in the topic...
  • 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!
  • Anonymous
    actually i learned much and deepy about lean and its tool and knew the difference between lean and six sigma i really enjoyed it to the max , it for sure will help me in my career .

    i work as a Lean Consultant at V-veer Ltd .
  • Luciano Ciorciari
    Hi, my name is Luciano Ciorciari, I am from Argentina, and I work for an international gelatin and collagen manufacturer company. My position at the company is Manufacturing Excellence Manager, so the course Lean Production gave me more insights about...
  • 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...
  • Vlad Ivankine 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...
  • Anonymous
    Another fantastic course. I got familiar with Lean while doing an operation management course during my master's. A lot of my questions were answered.
  • Anonymous
    Good morning, I have 20 years of Lean experience and even so the course was excellent, I reviewed and learned many things, thank you very much
  • 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
    This was the final course for Yellow Belt Certification. This final class has allowed me to look at my company's current processes for a segment of our business and help me evaluate how we can improve. This course has clarified the operation philosophies...
  • 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...
  • Profile image for Pablo Rojas
    Pablo Rojas
    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
    Hi everyone, I don't know which of the three Green Belt Certification courses was my favorite, but Lean Production is definitely a phenomenal course. It was short but condensed, it contains a lot of information but it is easy to understand and apply in...

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