Lean Manufacturing Program

Lean Manufacturing

Master Certificate

SS25 001 – Maize Week 2 Only
May 5-9, 2025
$3,400
Register

Location:

Ann Arbor, MI

Schedule:

Mon-Fri 8:30am-4:30pm ET
FA25 001 – Blue Week 2 Only
Oct 20-24, 2025
$3,400
Register

Location:

Ann Arbor, MI

Schedule:

Mon-Fri 8:30am-4:30pm ET

Master Certificate Summary

Week 2 Overviews

Credentials

Instructional Team

Master Certificate Summary

Go Blue Discounts
Instruction Time Completion Time CEUs
Lean Manufacturing
Master Certificate 		2 weeks + 1 additional week
(Week 2 you haven't yet taken) 		Canvas access ends after 30 days 12

After completing your Lean Manufacturing certificate, you can continue learning and earn a master certificate. Choose the Week 2 you have not yet taken (either Maize or Blue) and register to complete your third week of training. By participating in all three weeks of the course, you will gain a full understanding of Lean Manufacturing practices and can confidently use new tools, methods, and change management techniques.

Week 2 Overviews

*LAPTOP REQUIRED*

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

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

Week 2 (BLUE): Lean Tools & Practice

  • Learn a tool to rate an operation’s Lean state based on a quick tour
  • Understand how to rate Lean through visual clues
  • Learn how visual management motivates people and teams
  • Understand the relationship between Lean progress and cost savings in an operation
  • Learn how complexity and variability reduction relate to Lean improvement


Zingerman’s Mail Order Walk-Thru
610 Phoenix Dr, Ann Arbor, MI 48108

  • Learn the difference between standardization versus standards
  • Learn the background/history of standardized work
  • Internalize the steps to implementing standardized work
  • Demonstrate the application of the steps (defining product families, calculating takt time, performing standard work analysis, and developing standard work documents) in an academic case
  • Review the application of the standard work process in an industry case
  • Practice implementing the standard work process in a simulation
  • Learn how to train using standardize work leveraging the Job Instruction method
  • Learn how to use the simplify-eliminate-combine principle to reduce/eliminate material handling waste
  • Learn the role and impact of plan-for-every-part (PFEP) and lineside-back design
  • Learn the basic structure and operation of milk-run systems (fixed interval, variable quantity deliveries) and call systems (variable interval, fixed quantity deliveries) used in Lean plants.
  • Practice the above learnings by designing a milk-run system and a call system with your team for a manufacturing plant with known workstation locations and layout
  • Understand why it is not sufficient to have just a lean factory, and why to compete, one needs a lean and resilient supply chain
  • Understand supply chain design trade-offs, and how to measure and improve supply chain efficiency, and resilience.
  • Understand how geopolitical developments are affecting supply chain designs
  • Learn about the importance of mapping supply chains, and understanding how nodes in the supply chain can affect your manufacturing productivity.
  • Learn supply chain resilience through case-studies
  • Participate in a supply chain simulation where you design and price your product, pick suppliers (design your supply chain), plan production. 
  • Discuss the challenges faced in participants’ supply chains, and brainstorm ideas to improve the efficiency and resilience of the supply chains.
  • Understand the role of change management in a successful Lean implementation
  • Understand and gain the capability to implement change management using a structured (7-step) Lean change model
  • Apply the Lean change model in a simulation where you undertake Lean change in a complex, high-pressure environment
  • Apply the Lean change model to brainstorm ways to accelerate your company’s Lean transformation

Credentials

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Digital Badge

Digital badge earned after successful completion of this course.

Digital Certificate

Certificate will be awarded upon successful completion of this course.

Printed & Framed Certificate

A printed and framed certificate will be shipped to you upon completion.

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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