Lean enterprise is a process designed to bring about rapid improvements to an organization's performance through an overhaul of the value stream. It is composed of a comprehensive set of elements, rules, and tools that focus on value, waste elimination, and continuous incremental improvement.

As market forces dictate pricing and lead-time pressures, businesses need to focus on waste-free processes in order to grow margins and remain competitive. Lean uses specific concepts that are intended to provide excellent quality products, delivered on time, at the lowest total cost, and only on the specific demand of the customer. Companies transitioning to a lean culture are now seeing radical improvements in profitability, service levels, productivity, asset utilization, cash flow, inventory levels, product designs, quality, cycle times, and product costs.

The Lean Mastery Online Program contains clear, concise information on transforming an enterprise to lean. The program is packed with examples, photographs, graphics, quizzes, progress tests, case studies, and many interactive features that provide tips, "try this" exercises, and in-depth information.

Upon registering, you're given an initial six months to complete the program. Should you need more time, you may request a six-month extension at no additional charge.

Upon completion of this program, you'll:

• Recognize how the application of lean principles can substantially improve the operating and financial performance of any business
• Understand how to recognize and eliminate waste
• Know how to determine value added, non-valued-added, and non-value-added-but-required activities
• Be able to identify the value stream, how it’s mapped, and how to identify the areas that require improvement
• Be able to develop a road map and an implementation plan
• Understand policy deployment and why this is a critical part of any lean implementation process
• Recognize the fundamental importance of the Kaizen process, how it's used in every aspect of a lean implementation, and how it's used to change the culture
• Learn about the concept of design for manufacture and assembly and how design influences cost
• Gain a broad understanding of lean tools like 5S, Total Productive Maintenance (TPM), Kanban, visual workplace, error-proofing, and Scheduling
• Understand the role of accounting and how lean metrics must replace traditional metrics

1. Foreword
   1. Lean Enterprise Defined
   2. How It All Began
2. The Need for Change
   1. Why Change?
   2. Benefits of Lean
   3. The Evolution to Lean
   4. Touring a Traditional Operation
   5. Lean vs. Traditional Manufacturing
   6. Batch and Queue
   7. The Role of Management
   8. Organization Changes
   9. Resistance
   10. The Role of Education
3. Lean Theory
   1. Overview
   2. Waste
   3. The Types of Waste
   4. Provide Value
   5. Radical Change
   6. Continuous Incremental Improvement
   7. Lean Elements
      1. Value
      2. Value Stream
      3. Flow
      4. Pull
      5. Perfection
   8. Lean Rules
      1. Standard Work
      2. Limit Material Movement
      3. Limit People Movement
      4. Educate Everyone
   9. Lean Tools Overview
      1. Kaizen
      2. 5S
      3. TPM
      4. SMED
      5. Process Mapping
      6. Takt Time
      7. Line/Work Balancing
      8. Kanban
      9. Mistake Proofing
      10. Autonomation
      11. DFMA
      12. Visual Workplace
      13. 5 Why
      14. One-Piece-Flow
      15. Spider Charts
      16. Spaghetti Charts
      17. U-Shaped/Continuous Flow Cells
      18. Rabbit Chase
      19. Six Sigma
      20. Focused Factory
4. Kaizen
   1. Kaizen Defined
   2. Philosophy
   3. 10 Principals
   4. Problem Selection
   5. Guidelines
   6. Value-Added, Non Value-Added, Non-Value-Added Required
   7. Manufacturing Kaizen
      1. Batch and Queue
      2. Manufacturing Kaizen Goals
      3. Manufacturing Kaizen Aspects
      4. Manufacturing Kaizen Presentation
      5. Summary
   8. Administrative Kaizen
5. Value Stream Mapping
   1. VSM Defined
   2. Purpose of VSM
   3. Technology Used
   4. The Current State Map
   5. The Future State Map
   6. Strategy
   7. Getting Started
   8. The Team
   9. Developing a VSM
   10. VSM Approach
   11. Definitions and Icons
6. Transforming the Enterprise
7. SMED (Single Minute Exchange of Dies)/Quick Change
   1. Audi
   2. Goals
   3. Traditional Concepts
   4. Inventory
   5. Benefits
   6. Rules
   7. Internal vs. External Activities
   8. Methodology
   9. Observe and Document Current Process
   10. Separate Internals from Externals
   11. Develop Plan
   12. Observe and Document New Process
   13. Standardize New Process
   14. Celebrate
8. TPM (Total Productive Maintenance)
   1. Introduction
   2. Definition
   3. Alternatives
   4. Prevention Principles
   5. Obstacles
   6. Types of Breakdowns
   7. Deterioration
   8. How TPM is Implemented
   9. Overall Equipment Effectiveness (OEE)
   10. Calculating OEE
   11. The Six Big Losses
   12. Types of Maintenance
       1. Preventive
       2. Breakdown
       3. Corrective
       4. Predictive
       5. Maintenance Prevention
   13. TPM Tools
   14. Autonomous Maintenance
   15. 7 Steps to Autonomous Maintenance
   16. Skills Training
   17. TPM Strategy
9. 5S
   1. Introduction
   2. Definition
   3. Separate
   4. Sort
   5. Sweep
   6. Standardize
   7. Sustain
   8. Safety
10. DFMA (Design for Manufacture and Assembly)
    1. Definition
    2. Traditional Approach
    3. Concurrent Engineering
    4. DFMA Principles
    5. DFMA Rules
    6. Why DFMA?
    7. Design Techniques
    8. Design Process
    9. Design for Six Sigma Overview
    10. DFMA Benefits
    11. Product Release
11. Kanban
    1. Introduction
    2. Definition
    3. Pull vs. Push Systems
    4. Function
    5. Applications
    6. Information Flow
    7. Types
    8. Calculations
    9. Information Requirements
    10. Manufacturing Rules
    11. Planner Rules
    12. The Role of MRP
    13. Electronic Systems
    14. Inventory Carrying Costs
12. Other Lean Tools
    1. Standard Work
    2. Visual Workplace Management
    3. Error Proofing (Poka-Yoke)
    4. Scheduling and Leveling (Heijunka)
    5. Value Selling
13. Lean and Six Sigma Overview
14. Lean Accounting Overview
15. Implementing Lean
    1. Putting it All Together
    2. Lean Road Map
    3. Policy Development
    4. Lean Implementation Plan
    5. Lean Metrics

There are no specific prerequisites for this program. This program is for you if you're an  executive, manager, supervisor, professional, or anyone who needs to learn how to substantially improve business performance.

This program is compatible with the Windows XP and later operating systems and IE 7 and later browsers.

The most commonly used lean forms will be available for download in Microsoft Excel format. Many of these forms are interactive and will perform calculations or build charts to be used in presentations. If you don't have Excel on your computer, you can use a free download for an Excel viewer, which will be provided.

Brian Furlong is a seasoned senior executive with 30 years of experience in manufacturing and finance. After working domestically and internationally for major companies such as Emerson, Westinghouse, Invensys, and National Westminster Bank, Brian has in-depth knowledge of manufacturing and administrative processes. He has directed projects to start up plants in England, Ireland, Thailand, and Mexico and has completed acquisitions in England, China, and India. He's a passionate advocate of lean enterprise and has successfully completed implementation in numerous facilities in the United States, Mexico, Europe, and Asia.