Essential Lean Manufacturing for Management Consultants
- 4.5 hours on-demand video
- 1 article
- 28 downloadable resources
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- Certificate of Completion
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- Analyze production process
- Apply lean manufacturing techniques in practice
- Improve production process – make it faster, cheaper and at higher quality
- Calculate in Excel the potential impact of proposed changes
- Apply improvement techniques to other fields and industries
- Identify and remove bottlenecks
- Manage projects using critical chain methods
- Basic or intermediate Excel
- Basic knowledge of economics or finance
What is the aim of this course?
This course will help you drastically improve your knowledge and skills in optimizing production, and operations of any company through a series of practical cases. It is designed for people who want to become consultants, business analysts or have to run and optimize production on a daily bases. In the course you will learn 3 things:
How to understand any production or operational activities
How to optimize the production and operations in order to get more things done, cheaper at higher quality with less resources using elements from lean manufacturing, theory constraints
Where to look for savings and improvements, how to calculate potential savings in Excel and implement them
I will concentrate here on lean manufacturing techniques as well as things related to theory of constraints (removing bottlenecks and critical chain).
The course is based on my 12 years of experience as a consultant in top consulting companies and as a Board Member responsible for strategy, improvement and turn-arounds in biggest companies from FMCG, SMG, B2B sector that I worked for. On many occasions I had to optimize the whole production and operational side of the businesses I was responsible for. On the basis of what you will find in this course I have trained over 100 consultants, business analysts and managers who now are Production Directors, Operational Directors, COO, Investment Directors, Directors in Consulting Companies, Board Members etc. On top of that my courses on Udemy have already been taken by more than 45 000 students. The course you will take has been taken also by people from EY, Walmart, Booz Allen Hamilton, Dell, Walgreens and many more as a part of Udemy for Business.
I teach through cases so most of the lectures are case studies showing some business problems solved in Excel. There will be also overview of main techniques used in optimizing and running production. To every lecture you will find attached (in additional resources) the Excels shown in the Lecture so as a part of this course you will also get a library of ready-made analyses that can, with certain modification, be applied by you in your work.
Why I decided to create this course?
Most consultants and business analysts are terrible at organizing operational issues. They treat the operations, especially production, as a black-box and try to avoid it at any cost. Technical things overwhelm them and they shy away from them. This approach is not the right one as you find elements that resemble production everywhere. In hospitals most procedures performed are very similar to production issues. The same goes for running a call center, a chain of restaurants, a logistic company or a firm delivering specialized services. Everywhere you have operations that you can optimize by using techniques that I will show in this course. Production influence heavily other areas especially sales and marketing. Therefore, it is a good idea to have at least a general knowledge in production. The funny things is that to be good at production you do not even have to be technical at all. I have not finished any technical school and I am pretty good in finding significant improvements in production. One of the best Production Directors I know has finished Pedagogical Studies.
To sum it up, I believe that if you want to build or to find improvements in any business you should master techniques related to optimizing production. That is why I highly recommend this course not only to consultants or business analyst that have to advice their customer but also to owners, founders of businesses as well as production directors.
In what way will you benefit from this course?
The course is a practical, step by step guide loaded with tones of analyses, tricks, hints that will significantly improve the speed with which you find and analyze production. There is little theory – mainly examples, a lot of tips from my own experience as well as other notable examples worth mentioning. Our intention is that thanks to the course you will know:
How to understand production
How to optimize it
Where to look for savings and improvement in production
How to calculate the impact of proposed changes in Excel
You can also ask me any question either through the discussion mode or by messaging me directly.
How the course is organized?
The course is divided currently in 6 sections and will be adding new section to address other important issues. Currently you will find the following sections:
Introduction. We begin with little intro into the course as well as some general info on production
Basic methods of improving production. In the second section I will discuss the basic techniques that you can use to optimize your business. Here you will find the potential low hanging fruits. Here I will show you basic lean manufacturing methods as well as elements of theory of constraints. You will also see how to calculate potential savings in Excel
Continuous Flow. The ideal in production is the so called continuous flow -every go smoothly and fast. Products are being produced fast and cheap. In this section I will tell you how to achieve it. This is one of the pivotal element of lean manufacturing
Advanced methods of improving production. In section 4 I will continuous with more advanced way in which you can improve your production such as: SMED, TPM, Automation, Critical Chain
Capacity management. Apart from optimizing the production you have to think strategically and know when you have to add new capacity / factory. In this section I will show you how you can do that
Production planning. Production planning is the brain of production. If you get this wrong the other things won’t matter. In this section I will show you some ways in which you can analyze and improve production planning
I will be adding new sections and lectures in the coming months
You will be able also to download many additional resources
Excels with analyses shown in the course
Presentation of slides show in the course
Links to additional presentations and movies
Links to books worth reading
- Management Consultants
- Production Directors and Managers
- Business Analysts
- Small and medium business owners
- Startups founders
We begin with little intro into the course as well as some general info on productio
Most treat production as a black-box but if you want to be a great consultant you will have to get into details. In this lecture I will show you why it makes sense to go deeper into production and e I will talk about the important issues that you will master in this course
In this lecture I will talk about the important issues that you will master in this course
Most treat production as a black-box but if you want to be a great consultant you will have to get into details. In this chapter I will show you how to improve production results with simple methods and techniques and what it means in practice
In production you will know far less than the your customer’s team so you have to use smart ways to get to the bottom of the things. 5 Why is one of such methods. In this lecture I will show you how to use it in practice
Now imagine that you were asked to increase the production capacity of a factory. Try also to calculate the financial impact of the proposed scenarios. Before we look at specific scenarios we have to discuss 2 issues
What the production capacity depends on?
How to calculate monthly production capacity
In every company you have bottlenecks that limit your ability to go forward and deliver more goods and services. Here I will show you how to estimate what is the impact for the whole system and how you can remove improve them. I will use simple production example to show you the effect on the whole system. You will see how the bottleneck can shift from 1 shift to another. You will also learn how to prioritize where it make sense to invest to get the best results.
Before doing this lecture I strongly encourage you first to take the OEE lecture – we use the OEE concept here so if you are not familiar with it please start with OEE lecture as a warm-up.
5S in short is about cleaning your working station, putting everything in order and keeping it this way I will show you the stages, examples of 5S and how to check whether the business has truly implemented 5S
We are very fast to acquire, buy and collect because even if we do not use it know at some point (usually very distant in the future) specific thing may prove to be lifesaving. Most often, the staff we collect we do not use more than once (80/20 rules come into play. In this lecture I will show you how to get rid of unused things it in practice
The ideal in production is the so called continuous flow -every go smoothly and fast. Products are being produced fast and cheap. In this section I will tell you how to achieve it.
One of the ways to make the set-ups shorter is the so called SMED technique. I will show you how to use it
One of the biggest problem for efficiency is the so called Parkinson’s Law – Work expand so as to fill the time available for its completion. People when asked to evaluate the time certain things will take build in buffers. One of the ways to deal with it is the so called Critical chain. Here I will show you what it is
Apart from optimizing the production you have to think strategically and know when you have to add new capacity / factory. In this section I will show you how you can do that
In this lecture we show how you can measure and analyze what is the maximal reach of your B2B bussiness having in mind transportation costs and markups. We will provide you with fast way to identify potential customers and measure your targeted price on a specific foreign market
2-stage production planning (planning for assembling and bundles). In many cases you have to first prepare the components and then on the basis of this produce the end product. This requires certain amount of additional planning, especially taking into account that the same component can be in different end-products. I will show you here on the basis of example of cosmetics producer how to create such a production plan, assuming optimal production batches for components and taking into account the inventories.