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Lean Mastery

Lean enterprise is a process designed to bring about rapid improvements to an organization's performance through an overhaul of the value stream. It is composed of a comprehensive set of elements, rules, and tools that focus on value, waste elimination, and continuous incremental improvement. As market forces dictate pricing and lead-time pressures, businesses need to focus on waste-free processes in order to grow margins and remain competitive. Lean uses specific concepts that are intended to provide excellent quality products, delivered on time, at the lowest total cost, and only on the specific demand of the customer.

Companies transitioning to a Lean culture are now seeing radical improvements in profitability, service levels, productivity, asset utilization, cash flow, inventory levels, product designs, quality, cycle times, and product costs. The Lean Mastery Online Program contains clear, concise information on transforming an enterprise to lean. The program is packed with examples, photographs, graphics, quizzes, progress tests, case studies, and many interactive features that provide tips, "try this" exercises, and in-depth information.

6 Months / 60 Course Hrs
Open Enrollment

Offered in Partnership with your Preferred School

George Mason University Why this school? It's been chosen based on your location or if you've visited this school's website.

Financial Assistance Available*

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Learning Method

Instructor-led Self-Paced: Study at your own schedule

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Lean Mastery

Learning Method

Instructor-led Self-Paced: Study at your own schedule

Contact Us

Lean Mastery Details + Objective

Course Code: GES404

You Will Learn
  • Recognize how the application of Lean principles can substantially improve the operational and financial performance of any business
  • Understand how to recognize and eliminate waste
  • Know how to determine value added, non-valued-added, and non-value-added-but-required activities
  • Be able to identify the value stream, how it’s mapped, and how to identify the areas that require improvement
  • Be able to develop a road map and an implementation plan
  • Understand policy deployment and why this is a critical part of any lean implementation process
  • Recognize the fundamental importance of the Kaizen process, how it's used in every aspect of a Lean implementation, and how it's used to change the culture
  • Learn about the concept of design for manufacture and assembly and how design influences cost
  • Gain a broad understanding of Lean tools like 5S, Total Productive Maintenance (TPM), Kanban, visual workplace, error-proofing, and scheduling
  • Understand the role of accounting and how Lean metrics must replace traditional metrics
How the course is taught
  • Self-paced, online course
  • 6 months to complete
  • Open enrollment, begin anytime
  • 60 course hours
How you will benefit
  • Provide knowledgeable counsel to potential employers about how to better their processes
  • Become an essential asset at any company as you improve the flow of information and materials, making the company more productive
  • Stand out from competitors in being able to not only point out problems, but propose quality solutions
  • Understand how to use 5S, Total Productive Maintenance (TPM), and Kanban and apply that knowledge to a variety of settings

Lean Mastery Reviews

Lean Mastery Outline
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Introduction

Understand the fundamentals of Lean and its origins. Examine the benefits of Lean, how it compares to a traditional manufacturing model, and standard organizational changes associated with the process.

Lean Theory Overview

Learn about different types of waste and things that add or detract value from an organization. You’ll also cover the multiple Lean elements, as well as Lean rules and tools.

Kaizen and Value Stream Mapping

Master an understanding of Kaizen. You’ll learn about the philosophy behind Kaizen, its guidelines, and how to implement aspects of Kaizen into an organization. Move on to cover value stream mapping, including its purpose, technology behind it, and how to get started with creating your own value stream mapping.

SMED, TPM, 5S, and DFMA

Learn the fundamentals of Single Minute Exchange of Dies (SMED), Total Productive Maintenance (TPM), 5S, and Design for Manufacture and Assembly (DFMA).

Kanban

Understand the ins and outs of Kanban. You’ll receive an introduction and definition of the technique, along with its functions and applications.

Additional Lean Tools

Cover remaining Lean tools that have not yet been discussed in the course, including visual workplace management, Poka-Yoke, Heijunka, and more. Finally, you will learn about how Lean and Sigma Six can work together, the role of accounting in Lean, and how to implement Lean in various types of organizations.

Program Details
  1. Foreword
    1. Lean Enterprise Defined
    2. How It All Began
  2. The Need for Change
    1. Why Change?
    2. Benefits of Lean
    3. The Evolution to Lean
    4. Touring a Traditional Operation
    5. Lean vs. Traditional Manufacturing
    6. Batch and Queue
    7. The Role of Management
    8. Organization Changes
    9. Resistance
    10. The Role of Education
  3. Lean Theory
    1. Overview
    2. Waste
    3. The Types of Waste
    4. Provide Value
    5. Radical Change
    6. Continuous Incremental Improvement
    7. Lean Elements
      1. Value
      2. Value Stream
      3. Flow
      4. Pull
      5. Perfection
    8. Lean Rules
      1. Standard Work
      2. Limit Material Movement
      3. Limit People Movement
      4. Educate Everyone
    9. Lean Tools Overview
      1. Kaizen
      2. 5S
      3. TPM
      4. SMED
      5. Process Mapping
      6. Takt Time
      7. Line/Work Balancing
      8. Kanban
      9. Mistake Proofing
      10. Autonomation
      11. DFMA
      12. Visual Workplace
      13. 5 Why
      14. One-Piece-Flow
      15. Spider Charts
      16. Spaghetti Charts
      17. U-Shaped/Continuous Flow Cells
      18. Rabbit Chase
      19. Six Sigma
      20. Focused Factory
  4. Kaizen
    1. Kaizen Defined
    2. Philosophy
    3. 10 Principals
    4. Problem Selection
    5. Guidelines
    6. Value-Added, Non Value-Added, Non-Value-Added Required
    7. Manufacturing Kaizen
      1. Batch and Queue
      2. Manufacturing Kaizen Goals
      3. Manufacturing Kaizen Aspects
      4. Manufacturing Kaizen Presentation
      5. Summary
    8. Administrative Kaizen
  5. Value Stream Mapping
    1. VSM Defined
    2. Purpose of VSM
    3. Technology Used
    4. The Current State Map
    5. The Future State Map
    6. Strategy
    7. Getting Started
    8. The Team
    9. Developing a VSM
    10. VSM Approach
    11. Definitions and Icons
  6. SMED (Single Minute Exchange of Dies)/Quick Change
    1. Audi
    2. Goals
    3. Traditional Concepts
    4. Inventory
    5. Benefits
    6. Rules
    7. Internal vs. External Activities
    8. Methodology
    9. Observe and Document Current Process
    10. Separate Internals from Externals
    11. Develop Plan
    12. Observe and Document New Process
    13. Standardize New Process
    14. Celebrate
  7. TPM (Total Productive Maintenance)
    1. Introduction
    2. Definition
    3. Alternatives
    4. Prevention Principles
    5. Obstacles
    6. Types of Breakdowns
    7. Deterioration
    8. How TPM is Implemented
    9. Overall Equipment Effectiveness (OEE)
    10. Calculating OEE
    11. The Six Big Losses
    12. Types of Maintenance
      1. Preventive
      2. Breakdown
      3. Corrective
      4. Predictive
      5. Maintenance Prevention
    13. TPM Tools
    14. Autonomous Maintenance
    15. 7 Steps to Autonomous Maintenance
    16. Skills Training
    17. TPM Strategy
  8. 5S
    1. Introduction
    2. Definition
    3. Separate
    4. Sort
    5. Sweep
    6. Standardize
    7. Sustain
    8. Safety
  9. DFMA (Design for Manufacture and Assembly)
    1. Definition
    2. Traditional Approach
    3. Concurrent Engineering
    4. DFMA Principles
    5. DFMA Rules
    6. Why DFMA?
    7. Design Techniques
    8. Design Process
    9. Design for Six Sigma Overview
    10. DFMA Benefits
    11. Product Release
  10. Kanban
    1. Introduction
    2. Definition
    3. Pull vs. Push Systems
    4. Function
    5. Applications
    6. Information Flow
    7. Types
    8. Calculations
    9. Information Requirements
    10. Manufacturing Rules
    11. Planner Rules
    12. The Role of MRP
    13. Electronic Systems
    14. Inventory Carrying Costs
  11. Other Lean Tools
    1. Standard Work
    2. Visual Workplace Management
    3. Error Proofing (Poka-Yoke)
    4. Scheduling and Leveling (Heijunka)
    5. Value Selling
  12. Lean and Six Sigma Overview
    1. How Lean and Six Sigma Work Together
    2. DMAIC Overview
  13. Lean Accounting Overview
    1. The Role of Accounting
    2. Traditional v Lean Accounting
    3. Implementing Lean Accounting
  14. Implementing Lean
    1. Putting it All Together
    2. Lean Road Map
    3. Policy Development
    4. Lean Implementation Plan
    5. Lean Metrics
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Lean Mastery Instructors
Brian Furlong

Brian Furlong is a seasoned senior executive with 30 years of experience in manufacturing and finance. After working domestically and internationally for major companies such as Emerson, Westinghouse, Invensys, and National Westminster Bank, Brian has in-depth knowledge of manufacturing and administrative processes. He has directed projects to start up plants in England, Ireland, Thailand, and Mexico and has completed acquisitions in England, China, and India. He's a passionate advocate of lean enterprise and has successfully completed implementation in numerous facilities in the United States, Mexico, Europe, and Asia. Brian is the co-author of the book "The Elusive Lean Enterprise."

Lean Mastery Requirements / Prerequisites

There are no specific prerequisites for this program. This program is for you if you're an executive, manager, supervisor, professional, or anyone who needs to learn how to substantially improve business performance.

This program is compatible with the Windows XP and later operating systems and IE 7 and later browsers. The most commonly used lean forms will be available for download in Microsoft Excel format. Many of these forms are interactive and will perform calculations or build charts to be used in presentations. If you don't have Excel on your computer, you can use a free download for an Excel viewer, which will be provided.

Lean Mastery Frequently Asked Questions
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Can I register for programs if I am an international student?

Yes, because ed2go programs are online you never have to actually travel to the school. Most schools offer telephone or online registration.

How long does it take to complete a program?

All of our programs are self-paced and open enrollment, so you can start them when you want and finish them at your own pace. Upon registering, you're given six months to complete this program.

Do I have to buy additional materials?

All the materials you'll need are included in this course and are covered by your tuition.

Can I get financial assistance?

ed2go courses are non-credit courses, so they do not qualify for federal aid. In some states, vocational rehab or workforce development boards will pay for qualified students to take our courses.

What happens when I complete the program?

Upon successful completion of the program, you will be awarded a certificate of completion.

Am I guaranteed a job?

ed2go programs will provide you with the skills you need to obtain an entry-level position in most cases. We don't provide direct job placement services, but our facilitators and career counselors will help you build your resume and are available to give advice on finding your first job. Facilitators will also be available to use as a professional reference upon completion of the program. Potential students should always do research on the job market in their area before registering.

Who will be my instructor?

Each student is paired up with a facilitator for one-on-one interaction. The facilitator will be available (via e-mail) to answer any questions you may have and to provide feedback on your performance. All of our facilitators are successful working professionals in the fields in which they teach.

What software or hardware do I need in order to take online programs and what are the system requirements?

In order to take our online programs, you must have access to a computer and the Internet. You can access the program contents from any Web-enabled computer. You don't have to use the same computer to log-in to the program every time. We recommend that you have a word-processing program (Microsoft Word is best) and the latest version of Internet Explorer.

Can I use a Mac?

Yes, you can use a Mac for this program.

How can I get more information about the program?

If you have questions that are not answered on our website, please feel free to contact us via LIVE chat (click the button toward the top of the page). If you are visiting us during non-business hours, please feel free to send us a question using the "Contact Us" form to the right. You may also call us at (855) 534-3690. We will answer your questions promptly.

What if I don't have enough time to complete my program within the time frame provided?

The time allotted to complete your program has been calculated based on the number of hours for each program, so don't worry too much about not completing in time. If, after a concerted effort, you are still unable to complete, your Student Advisor will help you work out a suitable completion date. Please note that a fee will be charged for an extension.

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Talk to an admissions counselor
Speak with an official admissions counselor via . During non-business hours, please feel free to send us a question using the "Contact Us" button. You can also reach us by phone at (855) 520-6806.