Lean Mastery (60 hours)

Course Overview/Description

Lean Enterprise is a process designed to bring about rapid, step-change improvements to the performance of an organization through an overhaul of the value stream. It is comprised of a comprehensive set of elements, rules and tools that focus on value, the elimination of waste 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 primarily focuses on the relentless elimination of waste from all business activities. This is achieved through the use of 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, changeover times, product designs, quality, cycle times and product costs.

Lean Mastery contains clear, concise information on transforming an enterprise to Lean. The course 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. The program contains 60 hours of study that covers all of the Lean Enterprise concepts and was authored by people who have successful, hands-on, practical worldwide experience.

Upon registering, you are given an initial six months to complete the program. Should you need more time, you may request a 6-month extension at no additional charge.

Course Objectives

Upon completion of this course, the student will:

• Have gained a broad perspective of Lean Enterprise concepts and understand the interaction between the Lean elements, rules, and tools.
• Understand how Lean concepts can be applied to the different operational departments of a business, why the organization culture must change and why the Lean process must be institutionalized.
• Recognize how the application of Lean principles can substantially improve the operating and financial performance of any business.
• Understand the need to change and how to recognize and eliminate waste.
• Know how to determine value added, non-valued-added and non-value-added-but-required activities.
• Understand why everyone in the organization must participate and how this is accomplished.
• Know the importance of identifying the value stream, how it is mapped and how to identify the areas that require improvement.
• Gain a complete understanding of the elements of Flow and Pull and how these are applied.
• Learn why the pursuit of perfection is a way of life.
• Understand the fundamentals of Standard Work and how these can be used to help eliminate process variation.
• Recognize why the limit-people-and-materials rules are important and how they are integrated with the lean tools to eliminate waste.
• Understand how 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 this is used in every aspect of a Lean implementation and how it is 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 the concepts of 5S, Single Minute Exchange of Dies (Quick Change), Total Productive Maintenance (TPM), Kanban, Visual Workplace, Error-Proofing, Scheduling.
• Understand the role of accounting in the Lean implementation process and how lean metrics must replace traditional metrics. Find out how metrics drive behavior and how cost of quality impacts business performance.
• Get an overview of Six-Sigma and how Lean Enterprise and Six-Sigma are complimentary processes that are used to improve business performance.

Course Outline

I. Foreword

1. Lean Enterprise Defined
2. How It All Began

II. The Need for Change
1. Why Change?
2. Benefits of Lean
3. The Evolution to Lean
4. Touring a Traditional Operation
5. Lean v. Traditional Manufacturing
6. Batch and Queue
7. The Role of Management
8. Organization Changes
9. Resistance
10. The Role of Education

III. 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 Factor

IV. 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

V. 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

VI. Transforming the Enterprise

VII. SMED (Single Minute Exchange of Dies/Quick Change
1. Audi
2. Goals
3. Traditional Concepts
4. Inventory
5. Benefits
6. Rules
7. Internal v. 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

VIII. 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

IX. 5S
1. Introduction
2. Definition
3. Separate
4. Sort
5. Sweep
6. Standardize
7. Sustain
8. Safety

X. 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

XI. Kanban
1. Introduction
2. Definition
3. Pull v. 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

XII. Other Lean Tools
1. Standard Work
2. Visual Workplace Management
3. Error Proofing (Poka-Yoke)
4. Scheduling and Leveling (Heijunka)
5. Value Selling

XIII. Lean and Six Sigma Overview

XIV. Lean Accounting Overview

XV. Implementing Lean
1. Putting it All Together
2. Lean Road Map
3. Policy Development
4. Lean Implementation Plan
5. Lean Metrics

Prerequisites/Audience

There are no specific prerequisites for this course. The intended audience is executives, managers, supervisors, professionals and anyone who needs to learn how to substantially improve business performance.

PC Requirements/Materials Included

This course is compatible with the Windows Vista operating system.

The most commonly used 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 students do not have Excel on their computer, a free download for an Excel viewer will be provided.

Instructor Bio

Brian Furlong is a seasoned senior executive with 30 years experience in manufacturing and finance. 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 is a passionate advocate of Lean Enterprise, having successfully completed implementation in numerous facilities in the United States, Mexico, Europe and Asia.

Frequently Asked Questions (FAQs)

1. How do I register?
Click on the register button at the top of the page and follow the directions. It is important that you type all your information in the boxes, then print it out to sign.  Payment and sending instructions are in the bottom right corner of the form.

2. How much do the courses cost?
The fee is in the pink box at the top of the page.

3. Can I register for courses if I live outside the United States?
Yes you can!

4. Do I ever have go to the school I register with?
All of our courses are delivered entirely online, so you never have to go to a class or travel to the school.

5. How long does it take to complete a course?
All of our courses are self-paced and open enrollment. You can start and finish the course at your own pace. When you register for a course, you are given 180 days (6 months) to complete the course. If you need more time, extensions are available.

6. Do I have to buy additional materials?
All materials are included. The cost of materials is covered by your tuition. GES ships all materials via UPS ground service upon registration.

7. Can I get financial aid?
GES 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.

• GES provides a loan opportunity for students. Simply go to www.collegeloanapplication.com to apply for an easier qualifying loan at a slightly higher rate. Click here for more information on this loan program.

8. What happens when I complete the course?
Upon successful completion of the course, you will be awarded a certificate of completion from the school with which you registered. You must obtain a final passing grade of 70% or greater to be awarded a certificate.

9. Am I guaranteed a job?
GES courses will provide you with the skills you need to obtain an entry-level position in most cases. We do not provide direct job placement services, but our instructors will help you build your resume and are available to give advice on finding your first job. Instructors will also be available to use as a professional reference upon completion of the course. Potential students should always do research on the job market in their area before registering.

10. Who will be my instructor?
Each student is paired with a facilitator for one-on-one interaction. The facilitator will be available (via email or phone) 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.

11. What do I have to have in order to take an online course, and what are the system requirements?
In order to take our online courses, you must have access to a computer and the Internet (a normal dial-up connection is fine). You can access the course contents from any Web-enabled computer. There are no necessary plug-ins. You do not have to use the same computer to log-in to the course every time. We recommend that you have a word-processing program (Microsoft Word is best) and the latest version of Internet Explorer.

12. Can this course be taken on a Mac?
Yes.

Note: An IBM or IBM clone PC is any standard desktop computer that is not an Apple or MacIntosh. IBM and IBM clone PC's run some version of Windows as an operating system and come in many brands other than just IBM, such as Dell, Gateway, and Compaq just to name a few.

13. How can I get more information on the course?
All of the information we have is available online under our course catalog (www.gatlineducation.com). If you have questions that are not answered online, please feel free to email us at courseinfo@gatlineducation.com or call 817-870-2870. We will answer your questions promptly.

14. When can I start the course?
Our courses are all open enrollment. You can register and start the course as soon as you are ready.