LEAN: Learn The Underlying Science

Understand why and when various Lean principles work, using a quantitative approach.
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  • Lectures 33
  • Length 2.5 hours
  • Skill Level Intermediate Level
  • Languages English
  • Includes Lifetime access
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About This Course

Published 10/2015 English

Course Description

In this course, you will be able to learn the math and science underlying the Lean Principles. It helps you to diagnose process performance issues, and develop coherent and logical solutions quantitatively.

This course begins by explaining how organisations generate value, how value is tied to its financials and what are its drivers. You will also understand how simple building blocks could be used to construct complex value networks, not just linear value streams.

As you move forward in the course, you will learn about the Little's law, how it works, and how to apply it in practical situations. Little’s law is referenced throughout the course in various Lean concepts.

You will be familiarised with process quantities such as Flow Time, Throughput, WIP, etc., understand how are they related mathematically, and how to use these terms to diagnose problems and develop improvement solutions.

You will be able to appreciate why running operations at high utilisation reduces speed, and understand the effect of Variability on various process parameters.

You will learn and apply Capacity laws and understand the significance of V-U-T equation. You will be familiarised with the arithmetic to calculate process measures at the Value Network level.

Finally, you will learn and be able to apply the scientific basis behind the Lean Principles such as Line Balancing, One Piece Flow and Pull System.

What are the requirements?

  • No software is required.
  • Basic high school level arithmetic and ability to understand charts/ graphs is required
  • Basic familiarity with statistical quantities such as mean, standard deviation is helpful
  • Some work experience may be useful (though not required)

What am I going to get from this course?

  • 4 Quizzes, 27 Questions
  • Understand the science behind Lean Principles
  • Use simple building blocks to construct complex value networks
  • Understand how Little's law works and apply it in practical situations
  • Calculate quantities such as Throughput, WIP, etc
  • Appreciate why running operations at high utilisation reduces speed
  • Understand the effect of Variability
  • Learn and apply Capacity laws
  • Understand the significance of V-U-T equation
  • Learn the arithmetic of Value Networks
  • Explain the scientific basis behind the Lean Principles

What is the target audience?

  • Anyone who is interested in process improvement
  • Business owners who want to improve their operations
  • Managers who want to improve their operations/ processes
  • Lean Six Sigma Yellow Belts, Green Belts and even Black Belts will find this course very useful

What you get with this course?

Not for you? No problem.
30 day money back guarantee.

Forever yours.
Lifetime access.

Learn on the go.
Desktop, iOS and Android.

Get rewarded.
Certificate of completion.

Curriculum

Section 1: Basic Introduction to Lean
Course Introduction
Preview
03:20
05:32

The basics of Lean as a set of principles to increase value and reduce waste are discussed. The meaning of value is elaborated by contrasting customer value with the shareholder value.

Quiz 1: Basic Introduction to Lean
2 questions
Section 2: How is Value Delivered
04:19

SIPOC framework is introduced to explain how value is generated/ delivered, with several every day examples.

03:46

In this lesson, we discuss how complex networks can be built from simple building blocks. Basic building blocks such as buffers, activities, control flow, resources and equipment are explained.

Quiz 2: How is Value Delivered
5 questions
Section 3: Single Activity Analysis
08:31

Various quantities and measures of value networks are introduced. Performance metrics that give competitive advantage are discussed.

04:33
The concept of Takt time is introduced and explained with an example.
05:44

The most important "law" that helps to understand Lean concepts as well as design value networks is discussed with an example.

04:25

The definition and expression for capacity is introduced and elucidated with an numerical example.

09:28

Utilisation as a ratio of Throughput to Capacity is discussed. Variation and Capacity Laws are introduced.

09:48

VUT equation, or Kingman's formula is introduced and VUT equation can be leveraged to improve operations is explained.

05:36

Various causes of waiting time or delays, such as variation, availability, queuing policies, rework, etc., are explained.

Quiz 3: Single Activity Analysis
15 questions
Section 4: Value Network Analysis
03:04

The purpose and intent and analysing Value Networks is discussed.

03:56

Various Value Network motifs that could be used to create complex Value Networks are explained.

05:04

This lesson explains what are Bottlenecks and how can they be avoided or removed.

01:43

This lesson explains how Rework contributes to the waiting time or delays, resulting in higher flow times and WIP.

01:49

This lesson explains how to perform the arithmetic when two lines join in a Value Network.

02:09

This lesson explains the role parallel activities play in the dynamics of a Value Network.

Quiz 4: Value Network Analysis
5 questions
Section 5: Lean Principles Demystified
02:35

The Lean principle of Value Add vs Non Value Add is discussed.

12:14

The Lean concept of Line Balancing or Load Levelling is discussed quantitatively using quantities such as Throughput, Capacity, Takt Time, etc.

18:25

The concept of One Piece Flow is introduced and explained with a numerical example. It is demonstrated clearly that One Piece Flow does not work in all situations and the alternatives are discussed.

10:53

The concept of Pull System is introduced with an example and explained for both Make to Order (MTO) and Make to Stock (MTS) configurations. Kanban and CONWIP are discussed.

06:19

SMED, or Quick Changeover is introduced and the underlying science is explained using the Little's Law.

05:29

This lessons explains the scientific basis for Standardised Work.

Section 6: Worked Examples from the Quizzes
Quiz Question 1
01:00
Quiz Question 2
01:20
Quiz Question 3
02:07
Quiz Question 4
01:11
Quiz Question 5
03:48
Quiz Question 6
01:36
Quiz Question 7
01:48
Quiz Question 8
02:56
Quiz Question 9
01:25
Quiz Question 10
03:12

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Instructor Biography

Lean Business Academy, Data, Knowledge, Value

Lean Business Academy leverages decades of experience in Process Excellence, Operations Strategy, Lean Six Sigma, Data Science, Corporate Finance, Strategy, etc. in producing and delivering solid training content to learners worldwide. We have trained people across the industry sectors and have advised corporate clients across in UK, Europe and US.

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