print
Course Name
Lean Manufacturing Personal Training Library

Contact Hours: 24

Course Description

The Lean Manufacturing course provides a comprehensive introduction to lean manufacturing concepts, terminology, techniques, and practices. In the first unit students will learn how to identify (and eliminate) waste and how to use value-stream mapping to capture the current state and visualize the future state.
 
Overviews of the eight components of lean:

Value Stream Mapping, Workplace Organization, Predictability & Consistency, Set-up Reduction, TPM, Visual Factory, Support Processes, and Continuous Improvement are explored in Unit 2. Lean implementation strategies and practices are covered in Unit 3. (3 Units; 3 Assessments; Approximately 10 hours of training.) In the 5S: Workplace Organization course, the student will learn the fundamental concepts of the 5S’s that help improve quality and productivity. (The 5S’s stand for Sort, Set in Order, Shine, Standardize, and Sustain; these terms are rough translations from the original Japanese terms referring to a process to optimize workplace organization.) The training includes step-by-step guidelines for achieving the 5S’s as well as a roadmap to implement the 5S’s.

Many examples of 5S success stories are included throughout the training. (2 Units; 2 Assessments; Approximately 5 hours of training.) 8-D Problem-Solving (Eight Discipline) is a step-by-step problem-solving methodology popularized by Ford Motor Company. With the 8-D problem-solving process (or Global 8-D as Ford calls it), teams address and solve problems by uncovering and eliminating the root cause of the problem. The 8-D course includes tutorials on over 50 data analysis tools and helps the student determine when and where the various tools can most effectively be applied in the problem-solving process. (2 Units; 2 Assessments; Approximately 7 hours of training.)

Mistake Proofing Training includes a comprehensive background on techniques as well as the steps required to implement those techniques. Over 150 examples of mistake-proofing are included. (4 Units; 3 Assessments; Approximately 8 hours of training.)


Outcome
  • Learn how to develop current value-stream maps, identify waste, and formulate future state maps
  • Understand how the eight components (Value Stream Mapping, Workplace Organization, Predictability & Consistency, Set-up Reduction, TPM, Visual Factory, Support Processes, and Continuous Improvement)
  • Explore a roadmap for implementing lean and how to avoid common pitfalls
  • Understand team problem-solving methodologies
  • Recognize the importance of the use of data to solve problems
  • Learn how to use data analysis tools and techniques to identify and correct root causes of recurring problems
  • Discover how to use mistake-proofing techniques to prevent errors from occurring


Assessment
  • Each of the four courses is self-contained with exercises throughout that are self-assessment "quizzes"
  • Each of the four courses has End-of-Unit automated and self-scoring exams (called Challenges) that evaluate student progress, comprehension, and provide constructive feedback on areas of deficiency
  • Evaluation of student performance for each course will be based upon the following criteria: Final exams = 100% of course grade
  • Courses must be completed within 90 days



Outline

Lean Manufacturing Library

The Lean Manufacturing Library gives one learner access to four core Lean Manufacturing courses: Lean Manufacturing,5S’s: Workplace Organization, 8D Problem-Solving, and Mistake-Proof It!.

The Lean Manufacturing course provides a comprehensive introduction to lean manufacturing concepts, terminology, techniques, and practices. In the first Unit, students will learn how to identify (and eliminate) waste and how to use value-stream mapping to capture the current state and visualize the future state. Overviews of the eight components of lean: Value Stream Mapping, Workplace Organization, Predictability & Consistency, Set-up Reduction, TPM, Visual Factory, Support Processes, and Continuous Improvement are explored in Unit 2. Lean implementation strategies and practices are covered in Unit 3. (3 Units; 3 Assessments; Approximately 10 hours of training.) Contents include:

  • Unit 1 - Lean Concepts
  • Unit 2 - Lean Practices
  • Unit 3 - Implementing Lean

In the 5S: Workplace Organization course the student will learn the fundamental concepts of the 5S’s that help improve quality and productivity. (The 5S’s stand for Sort, Set in Order, Shine, Standardize, and Sustain; these terms are rough translations from the original Japanese terms referring to a process to optimize workplace organization.) The training includes step-by-step guidelines for achieving the 5S’s as well as a roadmap to implement the 5S’s. Many examples of 5S success stories are included throughout the training. (2 Units; 2 Assessments; Approximately 5 hours of training.) Contents include:

  • Unit 1 - 5S’s Step-by-Step
  • Unit 2 - 5S Implementation

8-D Problem-Solving (Eight Discipline) is a step-by-step problem-solving methodology popularized by Ford Motor Company. With the 8-D problem-solving process (or Global 8-D as Ford calls it), teams address and solve problems by uncovering and eliminating the root cause of the problem. The 8-D course includes tutorials on over 50 data analysis tools and helps the student determine when and where the various tools can most effectively be applied in the problem-solving process. (2 Units; 2 Assessments; Approximately 7 hours of training.) Contents include:

  • Unit 1 - Getting Started
  • Unit 2 - 8-Discipline Process

Mistake Proofing Training includes a comprehensive background on techniques as well as the steps required to implement those techniques. Over 150 examples of mistake-proofing are included. (4 Units; 3 Assessments; Approximately 8 hours of training.) Contents include:

  • Unit 1 - Mistake-Proofing Primer
  • Unit 2 - Effects of Mistake-Proofing
  • Unit 3 - Implementing Mistake-Proofing Solutions
  • Unit 4 - Mistake-Proofing in Action