Leadership Course

Lean Manufacturing

Maize

WEEK 1 & WEEK 2 MAIZE

Not Currently Scheduled
$6,900
Contact Us

Location: Ann Arbor, MI
Schedule: 8:30am-4:30pm ET

Course Summary

Learning Objectives

Course Overview

Credentials

Instructional Team

Course Summary

Go Blue Discounts
Instruction Time Completion Time CEUs
Lean Manufacturing 10 days Canvas access ends after 30 days 8

The Maize course includes the standard first week of Lean Manufacturing that focuses on the essentials. Week 1 is the same for both the Maize and Blue courses. When you return for the second week of the Maize course, you will learn about Lean methods and implementation. Together, the two weeks teach you how to use Lean manufacturing tools and methods through expert lectures, case studies, exercises, and simulations.

Learning Objectives

  • Know how the philosophy and core methods of Lean manufacturing apply to your business
  • Value stream map the current state of your material and information flow through the value chain — understand where the added value is for the customer
  • Identify waste and its root cause in the value stream
  • Develop future state vision of your Lean systems by using kaizens (improvement events)
  • Use the leadership skills needed to drive Lean initiatives

Program Overview

*LAPTOP REQUIRED*

Complete the two-week course to earn your Certificate. Within two years, complete a third week (the five-day Week 2 course you have not yet taken—Maize or Blue) to earn the Master Certificate.

Week 1: Lean Manufacturing Essentials

  • Understand the Lean Manufacturing principles and benefits
  • Understand continuous flow, pull, and standardized work
  • Understand value versus waste and how to identify waste
  • Participate in a hands-on simulation where you have opportunity to use the principles of Lean to improve flow
  • Learn how to construct a current state value stream map and what data to collect for the value stream map
  • Learn how to interpret the data and the current state to identify capacity constraints, bottlenecks, and waste
  • Understand the role and function of “process boxes” and “data boxes” in a value stream map 
  • Learn the key factors to consider and the key questions to ask to develop a future state map from the current state
  • Practice the above learnings through a team-based exercise to develop a current state and a future state map for a supplier company
  • Understand the differences between a pull and a push system
  • Understand different kinds of pull systems and their implementation details
  • Understand how much inventory is necessary (number of kanbans) in a pull system and how to compute these numbers
  • Understand EPEI (every product every interval) and the role of set-up reduction in pull system design
  • Understand how to extend pull to purchased parts
  • Practice concepts in case studies and simulation
  • Learn how to see the “big picture” by constructing a PQ-chart (aka ABC analysis) for your product families
  • Learn how to estimate equipment and labor requirements for a cell as well as allocating work among the operators assigned to the cell
  • Learn how to compute and place standard WIP in a cell
  • Practice the above learnings by designing with your team two cells: an assembly cell for laptops and a fabrication cell for a component 
  • Understand the history of Kaizen and be able to articulate the different types of Kaizen events
  • Learn how to structure waste walks as a form of improvement event
  • Learn how to formulate different Lean tools as a structured Kaizen event
  • Learn how to plan, structure, and carry out a Value Stream Mapping Kaizen event
  • Develop tips for improving the effectiveness of Kaizen event facilitation by focusing on team dynamics and personality profiles
  • Understand the role of the facilitator in running Kaizen events and gain tips to improve the effectiveness of this role
  • Learn and practice the three phases of conducting a Kaizen event: 1. Planning and Preparation, 2. Implementation, 3. Presentation, Celebration, and Follow-up

Week 2 (Maize): Lean Methods and Implementation

  • Understand key operational metrics (throughput, flow time, and WiP) and their drivers
  • Understand how to conduct capacity analysis to identify and alleviate bottlenecks
  • Understand the role of variability in reducing throughput and increasing WIP
  • Learn how to link operational improvements to financials
  • Practice concepts in case studies and simulation
  • Understand what is meant by “Lean Six Sigma”
  • Achieve a high level understanding of the Six Sigma methodology
  • Apply Six Sigma in a case study
  • Understand the link between variation and flow
  • Learn how to define Six Sigma projects from a value stream perspective
  • Learn how to operationalize the Lean Six Sigma roadmap
  • Practice applying the Process Maturity Matrix – Lean Six Sigma Roadmap to prescribe an approach to continuous improvement in a number of different situations
  • Learn the pathway from the current state to Lean Six Sigma and beyond
  • Learn the critical relationship between the layout of a facility and the current/future state value stream
  • Learn how to use spaghetti charting and compute parts-travel to assess/improve a layout
  • Practice the above learnings by working with your team to develop and assess the layout of a manufacturing plant   
  • Learn the role and impact of long-term facility planning and expansion considerations 
  • Learn the relevance and criticality of tying Lean systems to your organization’s strategic plan
  • Learn how to develop and execute a basic Hoshin Kanri (i.e., X-Matrix) to create a Lean systems strategic plan
  • Understand how to develop a charter for a Lean systems implementation committee based on your organization’s infrastructure
  • Learn about various Lean assessment models to evaluate the maturity of a Lean system in your organization
  • Practice the above learnings via team-based exercises and develop sample models that can be applied in your organization

Credentials

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Instructional Team

Izak Duenyas, Ph.D.

  • Lead Faculty
  • Associate Dean for Executive Programs, Herrick Professor of Business, Ross School of Business

Yavuz Bozer, Ph.D.

  • Lead Faculty
  • Professor, Industrial & Operations Engineering

Don Lynch, Ph.D.

  • Vice President of Quality, Strategy, and Transformation, SKF USA Inc.

JD Marhevko

  • Vice President of Quality, ZF Division U. Electronics & ADAS at ZF Group

Get Started

For more information or answers to any questions please email [email protected] or fill out the form.

Main Office:
2401 Plymouth Road, Suite A/B
Ann Arbor, MI 48105
(734) 647-7200
[email protected]

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