Lean

Lean manufacturing is a system designed to reduce waste and increase efficiency in manufacturing and other work environments. Lean processes include arranging work cells to reduce unnecessary movement, mistake-proofing work operations, standardizing work, and reducing or eliminating delays between steps in work operations.

The classes on Lean guide users through Lean terminology, principles, and practices, and helps users adopt Lean in their own workplace. The Lean manufacturing courses also provide foundational knowledge for those who are seeing Lean certification.


Class Functional Area Format Difficulty Version Department
123
Classes 1 to 10 of 26
Lean Manufacturing Overview 101

Lean Manufacturing Overview provides an introduction to the principles and terminology of lean strategies, including a discussion of the seven forms of waste, the definition of value-added, the difference between push and pull systems, and the importance of continuous improvement. ...

Related 1.0 Class:
Lean Manufacturing Overview 130
Foundational Online Beginner 2.0 Lean
Continuous Process Improvement: Managing Flow 124

This class covers the principles of continuous process improvement and the tools used to implement it.

Foundational Online Beginner 1.0 Lean
Continuous Process Improvement: Identifying and Eliminating Waste 125

This class covers process improvement through the identification and elimination of different kinds of waste.

Foundational Online Beginner 1.0 Lean
Developing a Lean Culture 135

This class covers strategies and tools for developing a lean culture within your company.

Foundational Online Beginner 1.0 Lean
Total Productive Maintenance 141

Total Productive Maintenance introduces users to TPM concepts and principles. This class provides an overview of each key TPM pillar, including autonomous maintenance, Five S, planned maintenance, quality maintenance, kaizen, training, safety, and office TPM. TPM combines aspects from lean ...

Related 1.0 Class:
Total Productive Maintenance Overview 150
Foundational Online Beginner 2.0 Lean
5S Overview 151

Five S Overview provides a thorough introduction to the purpose and process of 5S quality initiatives. This class includes separate discussions on each of the five steps, along with information on challenges, advantages, and possible assessment tools.Many companies implement quality ...

Related 1.0 Class:
5S Overview 155
Foundational Online Beginner 2.0 Lean
Cell Design and Pull Systems 161

Cell Design and Pull Systems provides an introduction to the origin, purpose, and advantages of cellular manufacturing. This class describes the basic characteristics of a work cell, along with how cells are planned, organized, and improved. Cell Design and Pull ...

Related 1.0 Class:
Cell Design and Pull Systems 160
Foundational Online Beginner 2.0 Lean
Intro to Six Sigma 171

Intro to Six Sigma provides a comprehensive introduction to the goals, methods, and tools used during Six Sigma initiatives. This class discusses the different roles in a Six Sigma team, DMAIC steps, and how to identify variation. Intro to Six ...

Related 1.0 Class:
Intro to Six Sigma 170
Foundational Online Beginner 2.0 Lean
Troubleshooting 181

Troubleshooting provides a comprehensive overview of various methods and tools used to troubleshoot problems. Troubleshooting often involves finding the root cause of a problem and being able to distinguish deviations from problems and early warning signs from warning signs. Many ...

Related 1.0 Classes:
Troubleshooting: Identifying Problems 180
Troubleshooting: Understanding Causes and Effects 182
Troubleshooting: Taking Corrective Actions 184
Foundational Online Beginner 2.0 Lean
Conducting Kaizen Events 191

Conducting Kaizen Events provides a comprehensive overview of kaizen events and how they work. A kaizen event is a focused project conducted by a cross-functional team that targets a particular problem area. Kaizen events produce both quantitative and qualitative benefits, ...

Related 1.0 Class:
Conducting Kaizen Events 260
Foundational Online Beginner 2.0 Lean
FormatFunctional AreaDepartment IDDepartmentClass IDClass NameDescriptionDifficultyVersionLanguageRelated Classes
OnlineFoundational230Lean220010 Lean Manufacturing Overview 101 Lean Manufacturing Overview provides an introduction to the principles and terminology of lean strategies, including a discussion of the seven forms of waste, the definition of value-added, the difference between push and pull systems, and the importance of continuous improvement. This class also highlights other quality concepts, such as single minute exchange of dies (SMED), inventory reduction, and Five S.Lean manufacturing approaches help companies optimize their processes through organization and waste reduction. Although change can be a challenge, more efficient, streamlined processes will ultimately lead to improved customer satisfaction. This class outlines the foundational concepts and vocabulary that every practitioner needs when beginning, or continuing, a lean initiative.Beginner2.0English(900130) Lean Manufacturing Overview 130
OnlineFoundational230Lean910120 Continuous Process Improvement: Managing Flow 124 This class covers the principles of continuous process improvement and the tools used to implement it.Beginner1.0English
OnlineFoundational230Lean910125 Continuous Process Improvement: Identifying and Eliminating Waste 125 This class covers process improvement through the identification and elimination of different kinds of waste.Beginner1.0English
OnlineFoundational230Lean910110 Developing a Lean Culture 135 This class covers strategies and tools for developing a lean culture within your company.Beginner1.0English
OnlineFoundational230Lean220040 Total Productive Maintenance 141 Total Productive Maintenance introduces users to TPM concepts and principles. This class provides an overview of each key TPM pillar, including autonomous maintenance, Five S, planned maintenance, quality maintenance, kaizen, training, safety, and office TPM. TPM combines aspects from lean manufacturing and quality initiatives to create a blended maintenance approach for both production and administrative areas. Improved safety, longer machine life, and increased employee involvement are just a few benefits of a well-executed TPM strategy. After taking this course, users will be able to describe the key components of total productive maintenance and their role in continuous improvement.Beginner2.0English(900150) Total Productive Maintenance Overview 150
OnlineFoundational230Lean220050 5S Overview 151 Five S Overview provides a thorough introduction to the purpose and process of 5S quality initiatives. This class includes separate discussions on each of the five steps, along with information on challenges, advantages, and possible assessment tools.Many companies implement quality initiatives to improve operations and eliminate waste. 5S is a quality method that promotes organization, efficiency, and team work through several sequential steps. After completing this class, users will understand the value of each 5S step and be better equipped to execute and evaluate 5S.Beginner2.0English(900155) 5S Overview 155
OnlineFoundational230Lean220060 Cell Design and Pull Systems 161 Cell Design and Pull Systems provides an introduction to the origin, purpose, and advantages of cellular manufacturing. This class describes the basic characteristics of a work cell, along with how cells are planned, organized, and improved. Cell Design and Pull Systems also includes a discussion of related quality concepts, such as takt time, cycle time, kanban systems, and error prevention. Work cells have become an integral component of many lean facilities due to their ability to streamline operations and decrease lead time. However, cells require planning, organization, and constant team effort. In order for the system to work, everyone must know his or her role in the cell. With this class, someone new to cellular manufacturing will be able to identify the benefits of work cells, use common quality terminology, and understand how supporting strategies, such as kanban and kaizen, come together to create an effective quality system.Beginner2.0English(900160) Cell Design and Pull Systems 160
OnlineFoundational230Lean220070 Intro to Six Sigma 171 Intro to Six Sigma provides a comprehensive introduction to the goals, methods, and tools used during Six Sigma initiatives. This class discusses the different roles in a Six Sigma team, DMAIC steps, and how to identify variation. Intro to Six Sigma also covers the tools practitioners use to track and analyze data, such as Pareto charts, frequency distribution charts, and run charts. Unlike some quality initiatives, Six Sigma offers tangible, measurable methods to gage a project's success. This class gives new practitioners the foundational knowledge needed to support a Six Sigma project by introducing them to key terminology and important data analysis tools.Beginner2.0English(900170) Intro to Six Sigma 170
OnlineFoundational230Lean220080 Troubleshooting 181 Troubleshooting provides a comprehensive overview of various methods and tools used to troubleshoot problems. Troubleshooting often involves finding the root cause of a problem and being able to distinguish deviations from problems and early warning signs from warning signs. Many tools are used to collect and interpret troubleshooting data, including check sheets, fishbone diagrams, and Pareto charts. The 5 Why technique, brainstorming, documentation, and troubleshooting teams are common methods of gathering troubleshooting data. Troubleshooting teams gather data in order to find possible solutions. Teams must test solutions to make sure they offer long-term results.Troubleshooting is an extremely important skill for all areas of industry. The information provided in this class prepares students to solve problems and understand how to work to prevent them in many different settings. Without this knowledge, students would not be able to solve problems effectively.Beginner2.0English(900180) Troubleshooting: Identifying Problems 180; (900182) Troubleshooting: Understanding Causes and Effects 182; (900184) Troubleshooting: Taking Corrective Actions 184
OnlineFoundational230Lean220090 Conducting Kaizen Events 191 Conducting Kaizen Events provides a comprehensive overview of kaizen events and how they work. A kaizen event is a focused project conducted by a cross-functional team that targets a particular problem area. Kaizen events produce both quantitative and qualitative benefits, although there are some potential challenges. During a kaizen event, a team analyzes the current state of the target and plans improvements for the future state. Kaizen events require preparation, training, and follow up.Kaizen events are an important part of lean manufacturing that often lead to dramatic changes and significant results. Kaizen events optimize processes and eliminate waste, which improves quality and reduces costs. After taking this class, students will have a foundational understanding of why kaizen events are held and what happens during a kaizen event. This familiarity prepares students to participate in, and eventually lead, kaizen events.Beginner2.0English(900260) Conducting Kaizen Events 260
OnlineFoundational230Lean220110 SPC Overview 211 SPC Overview offers a thorough introduction to the purpose and main concepts of statistical process control (SPC). This class describes different types of control charts, such as X bar, R, and P charts, and how these tools are used to determine if a process is in-control or out-of-control. Identifying and eliminating special cause variation is essential to creating quality products and reducing waste. SPC methods are an efficient, effective means to track variation and monitor processes. With SPC tools, manufacturers have the ability to find and fix issues before they lead to product problems. After taking this course, new and current personnel will understand commonly used control charts and recognize out-of-control signs, making them better equipped to contribute to quality control efforts at their facility.Intermediate2.0English(900210) SPC Overview 210
OnlineFoundational230Lean220130 Metrics for Lean 231 Metrics for Lean provides an introduction to the information and data used to track processes in lean manufacturing facilities, including takt time, cycle time, total time of operations, overall equipment effectiveness (OEE), and first-time quality. Metrics are measurable variables that can be tracked over time in order to identify errors or gauge progress. In lean facilities, metrics are tools manufacturers use to identify non-value added activities, streamline operations, and improve operations. After taking this class, users will be able to distinguish between broad and narrow metrics and calculate key values such as takt time and OEE. Understanding this information will help users contribute to lean initiatives and everyday continuous improvement efforts.Intermediate2.0English(900230) Metrics for Lean 230
OnlineFoundational230Lean220140 Process Flow Charting 241 Process Flow Charting provides an overview of the types and purposes of flow charts, including spaghetti diagrams, process maps, and value stream maps. This class describes the value of current- and future-state charts and how they contribute to quality initiatives.Process flow charts are a means to identify waste and inefficiencies in the production process. Choosing a flow chart depends on the needs and goals of the manufacturer; some charts use symbols and incorporate metrics, while others can simply be drawn by watching activities in the facility. With this class, new practitioners will learn about the development and use of flow charts and be better prepared to utilize these tools.Intermediate2.0English(900240) Process Flow Charting 240
OnlineFoundational230Lean220150 Strategies for Setup Reduction 251 The class Strategies for Setup Reduction presents several common strategies for decreasing setup, the activities required to prepare a product for processing. The single minute exchange of dies (SMED) method, which strives to reduce setups to under 10 minutes, is a core approach to setup reduction. SMED focuses on transitioning internal steps to external steps, which can be performed while machines are running. Additional SMED practices include using setup teams in parallel operations and prepping tools, paperwork, and materials. Standardization and special devices like one-turn and one-touch fasteners and intermediate jigs also help reduce setup times. Setup reduction is one of the many goals of lean manufacturing. Reducing setup times allows manufacturers to perform more setups for smaller, more-varied batches so that they can better respond to customer demands. After taking this class, users should be familiar with methods and understand the importance of setup reduction.Intermediate2.0English(900250) Strategies for Setup Reduction 250
OnlineFoundational230Lean220160 Total Quality Management Overview 261 Total Quality Management discusses the major principles of total quality management (TQM). TQM evolved from quality assurance methods, which emphasize quality by design. TQM is a management philosophy that focuses on customer satisfaction, since customers define quality. Efforts to improve quality are integrated throughout each stage of the industrial cycle. Leadership is responsible for creating and executing a strategic TQM plan, as well as establishing an open company culture that involves and empowers all employees. There are many methods that can be used to measure, analyze, and implement TQM.A company can be successful only if its customers are satisfied. TQM helps companies stay competitive by establishing a culture focused on customer satisfaction and continuous improvement. After taking this class, users should understand the importance of TQM and be prepared to contribute to total quality efforts in the workplace.Advanced2.0English(900255) Approaches to Quality Management 255; (900320) Managing Practices for Total Quality 320
OnlineFoundational230Lean910220 Management Tools: Problem Solving 270 This class covers lean tools that managers can use for problem solving and root cause analysis.Intermediate1.0English
OnlineFoundational230Lean910225 Management Tools: Product and Process Design 275 This class covers lean tools for managing product and process design.Intermediate1.0English
OnlineFoundational230Lean220210 Value Stream Mapping: The Current State 301 Value Stream Mapping: The Current State provides an introduction to the tools and process of value stream mapping. This course explains common value stream mapping (VSM) icons, the steps to creating a VSM, and outlines how to calculate key metrics, such as cycle time, parts per hour, and capacity. Users will also be guided through the development of a current state VSM for a company making a low-variety/high-volume product.Isolating and eliminating waste are critical to achieving streamlined operations in lean manufacturing. Current and future state value stream maps are one tool companies can use to track their processes and make plans for improvement. After taking this course, users will be able to identify VSM icons, calculate critical metrics, and contribute to current state VSM development.Advanced2.0English(900300) Value Stream Mapping: The Present State 300
OnlineFoundational230Lean900310 Six Sigma Goals and Tools 310 This class covers the Six Sigma DMAIC process improvement method and its primary goals, including the most common sub-steps and frequently used tools.Advanced1.0English
OnlineFoundational230Lean220220 Value Stream Mapping: The Future State 311 Value Stream Mapping: The Future State builds on concepts users used in Value Stream Mapping: The Current State. This class describes how to develop a future state value stream map, including how to evaluate a current state value stream map, target problem areas, and design a plan to reduce non-value added activities.A value stream map (VSM) is a process flow chart that manufacturers use to identify waste. The first step in value stream mapping is to create a current state map that represents the present flow of the facility. The next step is to identify areas of waste and develop a future state map. Future state maps represent changes the company can make to improve the facility's layout, production management, and communication systems. Reducing waste and streamlining processes is a goal in all manufacturing facilities. After completing these courses, users will be able to create VSMs and contribute to quality improvement efforts.Advanced2.0English(900305) Value Stream Mapping: The Future State 305
OnlineFoundational230Lean910310 Maintaining a Consistent Lean Culture 330 This class covers the methods and tools for maintaining a consistent lean culture within an enterprise.Advanced1.0English
OnlineFoundational230Lean910320 Transforming Lean into Business Results 340 This class teaches key processes and systems that optimize value flow and therefore produce optimum results in a lean system.Advanced1.0English
OnlineFoundational230Lean910330 Measuring Lean Systems 350 This class covers the metrics for measuring lean systems.Advanced1.0English
Instructor-LedFoundational230Lean921113 Lean Fundamentals: Firm Grasp on Waste and Getting 5S Right This course is designed to provide the participant with knowledge to be a critical practitioner with waste and 5S. Having a thorough understanding of waste is fundamental to everything else one might do with the lean body of knowledge. The class will focus on learning to see waste, developing approaches to eliminate waste, and finding ways to prevent waste from recurring. The 5S portion of the class will focus on developing a deep understanding of the why and how of 5S. Class will include techniques to audit and measure 5S performance. Participants will understand that 5S is a foundational part of the lean journey.  English
Instructor-LedFoundational230Lean921104 Kaizen Workshop This multi-day course is designed to have the participant learn how to problem-solve in a team environment through the use of Lean thinking. Using the principles of Lean, participants will work together to plan and implement improvements to a defined topic. Scope and boundaries will be established; the team will attack the issues until resolution is implemented. Most companies do not have enough time to effectively problem-solve, so band aid improvements are made. In Lean, kaizen is a way to use cross-functional resources in short periods—or bursts of dedicated time—to effectively improve processes. Kaizen is an intense, well-defined event used to help organizations problem-solve with a systematic approach. The approach utilizes people in a dynamic and fast-pace environment and usually at the origin of the issue being improved. Kaizen techniques utilize many different Lean tools such as line balancing, time observations, SMED, Value Stream Mapping, 5S techniques, and DMAIC.  English
Instructor-LedFoundational230Lean921112 Value Stream Mapping: Diagram the Information and Material Flows in Your Business A hands-on course that teaches students how to document and quantify material and information flow within their organizations. In today's global market, time is very important. The Value Stream Mapping techniques help everyone in the organization understand lead time. Lead time encompasses the total amount of time needed to convert raw material into a final product. Most organizations cannot separate the total time into manageable pieces. This class will guide the participant through the process used to capture and document the current material and information flows for a given process. Value Stream Mapping techniques allow a team of problem solvers to come together and SEE the door to door process exactly the same. Each participant will visit the Gemba (shop floor) and walk the door to door process. A standard set of icons will be taught and used during this session. A comprehensive case study is used to allow students to practice drawing value stream maps using the standard set of symbols and icons. Upon completion of the value stream maps, the participant will learn to look for strategic areas that could be improved. Each improvement idea will be analyzed for the impact to the lead time. After improvement ideas are identified, each participant will generate a future state map.  English