Lean Production

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.

• 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.

• This course reviews basic calculations used in production management. Therefore, basic math skills are necessary.