Essential Lean Manufacturing for Management Consultants
4.3 (580 ratings)
Course Ratings are calculated from individual students’ ratings and a variety of other signals, like age of rating and reliability, to ensure that they reflect course quality fairly and accurately.
4,485 students enrolled

Essential Lean Manufacturing for Management Consultants

Practical guide how to improve production and operations in a firm and analyze potential savings in Excel
4.3 (580 ratings)
Course Ratings are calculated from individual students’ ratings and a variety of other signals, like age of rating and reliability, to ensure that they reflect course quality fairly and accurately.
4,485 students enrolled
Created by Asen Gyczew
Last updated 4/2020
English
English [Auto-generated]
Current price: $53.99 Original price: $89.99 Discount: 40% off
23 hours left at this price!
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This course includes
  • 4.5 hours on-demand video
  • 1 article
  • 28 downloadable resources
  • Full lifetime access
  • Access on mobile and TV
  • Certificate of Completion
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What you'll learn
  • 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
Requirements
  • Basic or intermediate Excel
  • Basic knowledge of economics or finance
Description

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:  

  1. How to understand any production or operational activities  

  2. 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  

  3. 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:  

  1. How to understand production  

  2. How to optimize it  

  3. Where to look for savings and improvement in production  

  4. 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  

  1. Excels with analyses shown in the course  

  2. Presentation of slides show in the course  

  3. Links to additional presentations and movies  

  4. Links to books worth reading

Who this course is for:
  • Management Consultants
  • Production Directors and Managers
  • Business Analysts
  • Small and medium business owners
  • Startups founders
  • Controllers
Course content
Expand all 81 lectures 04:15:55
+ Introduction
6 lectures 11:16

We begin with little intro into the course as well as some general info on productio

Preview 02:31

In this lecture I will share some info on who am I and what is my experience

Preview 01:47

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

Preview 01:13

In this lecture I will talk about the important issues that you will master in this course

Preview 02:36

Here I will show you what to do if a blurry image appears

How to deal with Blurry image
02:04

Here I will show you how to find additional resources attached to the coruse like Excel files, presentations, links etc.

How to reach additional resources
01:05
+ Basic methods of improving production
26 lectures 01:30:37

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

Preview 02:17

Due to different of waste we only use 5% to create value. In this lecture I will show you 7 different types of waste that may occur at your business

Different types of waste
04:56

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

Preview 02:45

We show here how to use the so called OEE (Overall Equipment Efficiency) Analysis that shows you how efficient you are in using your resources. It is very useful for checking whether you use well machines and equipment

OEE
06:10

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. 

Removing bottlenecks
05:23

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

Removing bottlenecks – Example from production – Case Introduction
01:18

First let’s see what the production depends on assuming there is just 1 production stage

What the production capacity depends on?
04:15

We said that the production generally speaking depends on 3 drivers. Now let’s see how it looks like for the whole month

How to calculate the capacity for the whole month
04:21

Here we will discuss the sceanarios that we will analyze later

Removing bottlenecks – Example from production – Scenarios – Part 1
03:25

Here we will discuss the sceanarios that we will analyze later

Removing bottlenecks – Example from production – Scenarios – Part 2
01:24

Here we will discuss the available data that we will use to solve the case study

Removing bottlenecks – Example from production – Available Data
02:31

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.

Removing bottlenecks in Production – Solution
03:47

In this lecture we will see how you can present the result of the analysis in a for of graphs

Removing bottlenecks – Example from production – Graphs
02:00

You quite often have situation when people perform at different pace and with different results. You have to standardize them.

Standarization
03:14

Here I will show you in Excel the effect on standarization

Standarization - calculation in Excel
03:29

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

Preview 04:29

Here I show how to calculated the impact of 5S on cost in Excel

5S - calculation in Excel
02:11

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

Get rid of unused things - office
04:13

Kanban is a way in which you can drastically limit work in progress. I will show you in this lecture what it is and how it looks like in practice

Kanban introduction
03:36

I will show you how to calculate the impact of Kanban in Excel

Kanban in Excel
02:03

In this lecture I will show you how to take advantage of periods of lower activities using the so called Kanban

Kanban for services - examples
08:38

Zero defect rules is not about making zero mistakes. It is about finding mistakes as soon as possible and eliminating them. In this lecture I will show what it is and how to use it in practice

Zero defect rule
03:09

I will show you how to calculate the impact of universal workers in Excel

Universal worker
02:25

If you have specialized workers you end-up not using most of available resources. I will show you what you can achieve by having a more universal workers

Universal worker - Excel
02:35

Quite often you have one operator per one machine. This is often not efficient as machines just need feeding in the goods. 

1 worker 2 machines
03:32

I will show you how to calculate in Excel the impact of making the workers operate on more than 2 machines at the same time 

1 worker 2 machines - Excel
02:31
+ Continuous Flow
6 lectures 27:53

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.

Preview 04:09

Using a sandwich factory I will show you the mistakes people do when they try to create a continuous flow

How NOT to make continuous flow – sandwich factory
04:06

I will continue our example of sandwich factory. I will show you how the continuous flow should look like

How to make continuous flow – sandwich factory no kanban
03:11

I will continue our example of sandwich factory. We add the Kanban to the continuous flow

How to make continuous flow – sandwich factory with kanban
02:43

I show here example of continuous flow in services

Continuous flow in services
07:24

Sometimes it makes sense to have instead of continuous flow the so called smart batching. Here we continue the previous example from service company to show how it could look like

Smart batching
06:20
+ Advanced methods of improving production
9 lectures 27:35

I will show you how to use similar to OEE concept on people the so called Overall Labor Efficiency that shows you what is the potential for improving things done by people

OLE vs OEE
03:10

Before you start analyzing the waste you have to somehow group it by stages of occurrence and type of waste. I will show you in this lecture how you can approach this subject

Waste analysis
02:52

Before you start analyzing the waste you have to somehow group it by stages of occurrence and type of waste. I will show you in this lecture how you can approach this subject

Set-ups
02:48

One of the ways to make the set-ups shorter is the so called SMED technique. I will show you how to use it

Preview 03:01

Imagine that you are in a fish factory.  How much money are you loosing and how you can improve it

SMED - example from fish industry - case
01:21

In this lecture I show you the solution to the case you had to solve in the previous lecture

SMED - example from fish industry - solution
03:25

Apart from production people you will have a lot of so called maintenance guys that are fixing the machines. For this are we used the so called TPM

TPM
03:58

In more and more cases you have to find way to replace or support people with machines to lower down production costs

Automation - Introduction
03:44

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

Preview 03:16
+ Capacity management
5 lectures 14:28

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

Preview 02:07

Here I will show you how to manage capacity depending on your industry and demand forecast. 

How to manage capacity?
03:41

Locations of some factories depends on the so called supplier catchment area. You are looking for area where you have sufficient amount of resources or suppliers. Here we will see how catchment area influences decision on capacities

Supplier catchment area
02:26

The customer catchment area is important in picking the right location for the factory. Both B2B as well as B2C. Here I will show you how to approach this subject

Customer catchment area
02:24

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

Catchment area / reach analysis - B2B
03:50
+ Production planning.
2 lectures 12:09

In this lecture you will learn how to calculate optimal batches and how to estimate savings when comparing to actuals batches. We will use his an example of juice producer

Optimal production batch analysis - FMCG
06:37

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.

2-stage production planning
05:32
+ Case study - Optimizing processess in the store using Lean manufacturing
26 lectures 01:11:16

In this secgtion I show you how to optimize processes in the store. I will use here real case of a company from home improvement / DIY sector. You will get also the model we used to calculate costs

Optimization of in-store processes - Introduction
04:26

Workshop was very important as I was getting a team that I did not know and that did not trust me. On top of that they did not know how to optimize processes. I will show you in this sections what were the goals of the workshop 

Workshop - Introduction
02:09

In this section you will see what kind of goals were presented to the project team

Workshop – the scope of the project
03:01

The team had no previous experience in process optimization. In this section I will show you the techniques  that we were using to optimize the processes 

Workshop – Tools overview
02:07

Here you will find a short introduction to Lean manufacturing.  

Lean manufacturing - introduction
04:56

Here you will find a short introduction to theory of constraints 

Theory of constraints - introduction
03:14

Here you will find a short introduction to Queuing problem 

Queuing problem - introduction
03:34

Here you will find a short introduction to OEE 

OEE - introduction
03:10
Workshop – defining metrics and cost drivers
02:13

Here I will show you how in groups for chosen process the team has chosen the KPIs and cost drivers 

Workshop – optimizing 1 process
02:34

In this lecture I will show you an example of 1 process that was optimized with the team. I used this to show them the proper way of defining the KPIs, cost drivers and optimizing the process using this data

Workshop – optimizing 1 process - Excel file
02:17

Finally, during the workshop I show them the timeline of the project to get confirm that the project is doable within this ambitions timeline 

Workshop – timeline of the project
01:21

In section 4 I show you how to optimize      processes in the store. I will use here real case of a company from home      improvement / DIY sector. You will get also the model we used to calculate      cost

Introduction to in-store process optimization case
03:00

In this lecture I will show you some information on what we achieved during the process optimization and how the test store looked like

The store and the processes
01:24

Here I will show you how we optimized the process of changing prices in the store and what savings we managed to generate

Price Change
03:14

Here I will show you how we optimized the process of changing prices in the store and what savings we managed to generate

Price Change - calculation in Excel
02:24

Here I will show you how we optimized the process of shelf replenishment in the store and what savings we managed to generate

Shelf replenishment
02:55

Here I will show you how we optimized the process of shelf replenishment in the store and what savings we managed to generate

Shelf replenishment - calculation in Excel
02:23

Here I will show you how we optimized the process of advising customers in the store and what savings we managed to generate

Advising customers - Introduction
02:52

Here I will show you how we optimized the process of advising customers in the store and what savings we managed to generate

Advising customers - General solution
03:17

Here I will show you how we optimized the process of advising customers in the store and what savings we managed to generate

Advising customers - Details and results
03:43

Here I will show you how we optimized the process of advising customers in the store and what savings we managed to generate

Advising customers - calculation in Excel
01:49

Here I will show you how we optimized the process at cash till and info point in the store and what savings we managed to generate

Cash till and info point
01:54

Here I will show you what other potential improvements we suggested in order to sell new projects

Other potential improvements
02:25

In this lecture I will show the estimation of cost

Process cost estimation by groups
02:03

In this lecture I will show the estimation of costs and savings achieved during the project


Summary of all costs and savings
02:51
+ Conclusions
1 lecture 00:41
Bonus Lecture: up to 90% discounts for all my courses
00:41