Essential Lean Manufacturing for Management Consultants
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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 (61 ratings)
Instead of using a simple lifetime average, Udemy calculates a course's star rating by considering a number of different factors such as the number of ratings, the age of ratings, and the likelihood of fraudulent ratings.
1,941 students enrolled
Created by Asen Gyczew
Last updated 8/2017
English
Price: Free
Includes:
  • 2.5 hours on-demand video
  • 1 Article
  • 14 Supplemental Resources
  • Full lifetime access
  • Access on mobile and TV
  • Certificate of Completion
What Will I 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
View Curriculum
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.

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 is the target audience?
  • Management Consultants
  • Production Directors and Managers
  • Business Analysts
  • Small and medium business owners
  • Startups founders
  • Controllers
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Curriculum For This Course
46 Lectures
02:42:16
+
Introduction
4 Lectures 08:07

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

Introduction
02:31

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

About me
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

Why knowing production issues is important?
01:13

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

What subjects we will talk about?
02:36
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Basic methods of improving production
19 Lectures 01:11:23

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

Introduction to improving production
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

5 Whys
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 - content marketing example
05:23

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 - production example
03:47

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

5S - Introduction
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

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
02:35

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

Universal worker - Excel
02:25

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
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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.

Continuous Flow - Introduction
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
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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

SMED - Introduction
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

Critical chain
03:16
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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

Why you need to do capacity management?
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
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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
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Conclusions
1 Lecture 00:49
Bonus Lecture: up to 90% discounts for all my courses
00:49
About the Instructor
Asen Gyczew
4.3 Average rating
824 Reviews
18,459 Students
22 Courses
Expert in performance improvement, turnaround and startups

Expert in performance improvement, startuping and turning-around companies with significant experience both in management as well as in supervision of medium size companies (EUR 20 – 40 million) as well as startups.

Specialties:

Functional experience: performance improvement, strategy development, startups, intrapreneurship, post-merger integration and cost reduction, due diligence;

Industry experience: SMCG (domestic appliances, furniture, ceramic tiles), FMCG (cosmetics, juice, meat), retail (electronics, convenience shops, pharmaceuticals, DIY, vending), B2B (aluminum system, plywood, alcohol, reagents, loading systems), services (MRO, consulting, outsourcing)

Countries: Poland, Serbia, Russia, Ukraine