Lean Mastery

This Lean Mastery Online Training Program contains clear, concise information on transforming a business enterprise and making it lean.
Temecula, CA P.O. Box 760,, Temecula, CA 92593
(951) 9723600

Course at a Glance

Mode of learning : Online - Instructor Lead(LVC)

Domain / Subject : Business & Management

Function : General

Trainer name : Brian Furlong

Duration : 60 Hours

Difficulty : Medium

Lean Mastery

A lean business eliminates waste and focuses on providing quality products and services on time and at a low cost. This Lean Mastery Online Training Program contains clear, concise information on transforming a business enterprise and making it lean. This online certificate program is offered in partnership with major colleges, universities, and other accredited education providers.


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


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.


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.

All of our programs are self-paced and open enrollment, so you can start them when you want and finish them at your own pace. 

Course Syllabus


  • Lean Enterprise Defined
  • How It All Began

The Need for Change

  • Why Change?
  • Benefits of Lean
  • The Evolution to Lean
  • Touring a Traditional Operation
  • Lean vs. Traditional Manufacturing
  • Batch and Queue
  • The Role of Management
  • Organization Changes
  • Resistance
  • The Role of Education

Lean Theory

  • Overview
  • Waste
  • The Types of Waste
  • Provide Value
  • Radical Change
  • Continuous Incremental Improvement
  • Lean Elements
    • Value
    • Value Stream
    • Flow
    • Pull
    • Perfection
  • Lean Rules
    • Standard Work
    • Limit Material Movement
    • Limit People Movement
    • Educate Everyone
  • Lean Tools Overview
    • Kaizen
    • 5S
    • TPM
    • SMED
    • Process Mapping
    • Takt Time
    • Line/Work Balancing
    • Kanban
    • Mistake Proofing
    • Autonomation
    • DFMA
    • Visual Workplace
    • 5 Why
    • One-Piece-Flow
    • Spider Charts
    • Spaghetti Charts
    • U-Shaped/Continuous Flow Cells
    • Rabbit Chase
    • Six Sigma
    • Focused Factory?


  • Kaizen Defined
  • Philosophy
  • 10 Principals
  • Problem Selection
  • Guidelines
  • Value-Added, Non Value-Added, Non-Value-Added Required
  • Manufacturing Kaizen
    • Batch and Queue
    • Manufacturing Kaizen Goals
    • Manufacturing Kaizen Aspects
    • Manufacturing Kaizen Presentation
    • Summary
  • Administrative Kaizen

Value Stream Mapping

  • VSM Defined
  • Purpose of VSM
  • Technology Used
  • The Current State Map
  • The Future State Map
  • Strategy
  • Getting Started
  • The Team
  • Developing a VSM
  • VSM Approach
  • Definitions and Icons

SMED (Single Minute Exchange of Dies)/Quick Change

  • Audi
  • Goals
  • Traditional Concepts
  • Inventory
  • Benefits
  • Rules
  • Internal vs. External Activities
  • Methodology
  • Observe and Document Current Process
  • Separate Internals from Externals
  • Develop Plan
  • Observe and Document New Process
  • Standardize New Process
  • Celebrate

TPM (Total Productive Maintenance)

  • Introduction
  • Definition
  • Alternatives
  • Prevention Principles
  • Obstacles
  • Types of Breakdowns
  • Deterioration
  • How TPM is Implemented
  • Overall Equipment Effectiveness (OEE)
  • Calculating OEE
  • The Six Big Losses
  • Types of Maintenance
    • Preventive
    • Breakdown
    • Corrective
    • Predictive
    • Maintenance Prevention
  • TPM Tools
  • Autonomous Maintenance
  • 7 Steps to Autonomous Maintenance
  • Skills Training
  • TPM Strategy


  • Introduction
  • Definition
  • Separate
  • Sort
  • Sweep
  • Standardize
  • Sustain
  • Safety

DFMA (Design for Manufacture and Assembly)

  • Definition
  • Traditional Approach
  • Concurrent Engineering
  • DFMA Principles
  • DFMA Rules
  • Why DFMA?
  • Design Techniques
  • Design Process
  • Design for Six Sigma Overview
  • DFMA Benefits
  • Product Release


  • Introduction
  • Definition
  • Pull vs. Push Systems
  • Function
  • Applications
  • Information Flow
  • Types
  • Calculations
  • Information Requirements
  • Manufacturing Rules
  • Planner Rules
  • The Role of MRP
  • Electronic Systems
  • Inventory Carrying Costs

Other Lean Tools

  • Standard Work
  • Visual Workplace Management
  • Error Proofing (Poka-Yoke)
  • Scheduling and Leveling (Heijunka)
  • Value Selling

Lean and Six Sigma Overview

  • How Lean and Six Sigma Work Together
  • DMAIC Overview

Lean Accounting Overview

  • The Role of Accounting
  • Traditional v Lean Accounting
  • Implementing Lean Accounting

Implementing Lean

  • Putting it All Together
  • Lean Road Map
  • Policy Development
  • Lean Implementation Plan
  • Lean Metrics


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