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 series, learners will earn the Technical University of Munich Lean Six Sigma Yellow Belt Certification, confirming mastery of the fundamentals of Lean Six Sigma to a Yellow Belt level, based on the American Society of Quality's Body of Knowledge for the Certified Six Sigma Yellow Belt.
Week 1: Introduction and Identification of Waste
Review of the rise of mass production and the challenge presented by Japan's Toyota Production System, and introduce the core concepts of Lean: Quantity Control, Quality Control, and Waste and Cost Control. Understand the relationship between productivity and waste and discuss the well-known 7 wastes from the Toyota Production System.
Week 2: Continuous Flow
Perform process analysis, to identify bottlenecks and calculate resource capacity and resource utilisation. Understand the impact of variability in our systems on inventory and process time and discuss the importance of Takt, the drumbeat of the customer demand, in Lean Production.
Week 3: Adding Flexibility
Calculate the impact of setup times on process capacity when we introduce flexibility and how batching can rescuing this impact at the expense of higher inventories and flow times (waste). Discuss and calculate the best-practice metric, Overall Equipment Effectiveness, to measure availability, performance, and quality losses in our system. Gain an understanding of Total Productive Maintenance its role in Lean Production.
Week 4: Pull Systems
We then look at how pull systems as part of Quantity Control present opportunities to improve productivity and reduce waste in Lean Producing, including Total Productive Maintenance, SMED, mixed-mode production, and Just-in-Time manufacturing using kanbans.
Week 5: Workplace Organisation and Visualization
Introduction to the practices of Workplace Visualisation and 5S, Sort, Straighten, Shine, Standardize, Sustain, for establishing a work environment to support quality and Lean Production
Week 6: Quality and Productivity
Understand methods of quality control including the critical concept of Kaizen, the Japanese practice of continuous improvement, and other methods to eliminate waste including poka yoke and jidoka and andon, to increase productivity and quality.
Martin Grunow and Holly Ott