Lean Mastery

A lean business eliminates waste and focuses on providing quality products and services on time and at a low cost. This Lean Mastery Online Training Program contains clear, concise information on transforming a business enterprise and making it lean. This online certificate program is offered in partnership with major colleges, universities, and other accredited education providers.

Objective 

  • Upon completion of this program, you'll:
  • Recognize how the application of lean principles can substantially improve the operating 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

PMP, Project Management Professional, Project Management Professional (PMP), PMBOK, PgMP, PMI-RMP, CAPM, PMI-SP, PMI Scheduling Professional (PMI-SP) and the PMI REP Logo are registered marks of the Project Management Institute.

Details

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. This program/course is a good choice for those looking for project management experience and those aspiring to obtain a credential from PMI. It's also an excellent choice for existing PMI credential holders looking for an approved activity for continuing certification PDUs. At the end of this course, you'll be eligible to receive 60 PDUs, which is the equivalent to 60 program hours. You will need to create an account on pmi.org and add this course to your account in order to qualify for 60 PDUs. ed2go is an approved provider, R.E.P. #3213. Please visit pmi.org to learn more about PMI credentials and how they may fit into your continuing education plans. (This course aligns to the PMI Talent Triangle™.)

For the Talent Triangle breakdown of PDUs for this course, please Click Here.

Upon registering, you're given six months to complete the program.

  • Registration + Fees

    Begins: Open enrollment | REGISTER

    Course: OLMX800.01

    Tuition: $2,195

  • Outline

    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
  • Requirements

    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.

    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.

  • Instructor

    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."

  • FAQs

    1. 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.

    2. 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.

    3. Do I have to buy additional materials?

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

    4. 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.

    5. What happens when I complete the program?

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

    6. 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.

    7. 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.

    8. 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.

    9. Can I use a Mac?

    Yes, you can use a Mac for this program.

    10. 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 1-855-520-6806‪1-855-520-6806 FREE‬. We will answer your questions promptly.‬‬‬‬‬‬‬‬‬

    11. When can I start the program?

    Our programs are all open enrollment. You can register and start the program as soon as you are ready.

    Please note: Once the program curriculum is accessed online or through submission of a material shipment confirmation, refunds cannot be issued.

    12. What does the PMI R.E.P. logo signify, and how does it help me?

    ed2go is a global Registered Education Provider for the Project Management Institute (PMI). Registered Education Providers (R.E.P.s) offer programs and courses that are preapproved for professional development units through PMI and have been reviewed by a project management professional (PMP) to ensure that they meet PMI's expectations for professional development in project management. This program/course is a good choice for those looking for project management experience and those aspiring to obtain a credential from PMI. It's also an excellent choice for existing PMI credential holders looking for an approved activity for continuing certification PDUs. At the end of this course, you'll be eligible to receive 60 PDUs, which is the equivalent to 60 program hours. You will need to create an account on pmi.org and add this course to your account in order to qualify for 60 PDUs. ed2go is an approved provider, R.E.P. #3213. Please visit pmi.org to learn more about PMI credentials and how they may fit into your continuing education plans. (This course aligns to the PMI Talent Triangle™.) For the Talent Triangle breakdown of PDUs for this course, please Click Here. 13. 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.

  • Reviews

    "I thought the course was very thorough and easy to follow"."
- K.W., Trident Technical College

    "My instructor established an open line of communication and a quick turn-around to any concerns/questions." 
- T.W., California State University, East Bay

    "The course material was easy to follow and with it being an online course I was able to complete it at my own pace and time." 
- R.T., Clark College

    "The facilitator, Brian Furlong, provided in-depth responses to my questions and encouraged me throughout the course." 
- S.G., Pierce College

    "My facilitator Brian Furlong was extremely helpful and always responded to my questions. The staff at Rutgers and ed2go was very helpful. I would highly recommend both institutions to anyone who asked. In fact, in my new position I'm going to see if there's funding to have some of my co-workers attend the Lean Mastery course. I have been involved in Lean Enterprise for almost 10 years and this course covers everything an individual or organization needs to know in going forward with the implementation of lean systems.
" - J.G., Rutgers, The State University of New Jersey

    "For my job I have to travel 50% of the time and don’t always have access to the internet. A really nice feature of the course was the downloadable chapters in .PDF format. This allowed me to take the course while flying and away from my home office.
" - M.W., Moraine Park Technical College

    "My overall satisfaction is with the online flexibility while you are working. Thanks ed2go!
" - B.F., George Mason University