George Mason University OCPE Programs

Lean primarily focuses on the relentless elimination of waste from all business activities. This is achieved through the use of 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, changeover times, product designs, quality, cycle times and product costs.

Lean Mastery contains clear, concise information on transforming an enterprise to Lean. It 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. The program contains 60 hours of study that covers all of the Lean Enterprise concepts and was authored by people who have successful, hands-on, practical worldwide experience.

FEATURES

This nationally recognized Lean Enterprise Mastery online certificate training course contains clear, concise information on transforming a business enterprise to Lean. This Lean Mastery certificate 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. The program covers all Lean Enterprise concepts. This online program is only offered in partnership with major colleges and universities.

TOPIC HIGHLIGHTS

Foreword
1. Lean Enterprise Defined
2. How It All Began
The Need for Change
1. Why Change?
2. Benefits of Lean
3. Touring a Traditional Operation
4. Lean v. Traditional Manufacturing
5. Batch and Queue
6. The Role of Management
7. Organization Changes
8. Resistance
9. The Role of Education
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
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
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
Transforming the Enterprise
SMED (Single Minute Exchange of Dies)/Quick Change
1. Audi
2. Goals
3. Traditional Concepts
4. Inventory
5. Benefits
6. Rules
7. Internal v. 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
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
5S
1. Introduction
2. Definition
3. Separate
4. Sort
5. Sweep
6. Standardize
7. Sustain
8. Safety
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
Kanban
1. Introduction
2. Definition
3. Pull v. 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
Other Lean Tools
1. Standard Work
2. Visual Workplace Management
3. Error Proofing (Poka-Yoke)
4. Scheduling and Leveling (Heijunka)
5. Value Selling
Lean and Six Sigma Overview
Lean Accounting Overview
Implementing Lean
1. Putting it All Together
2. Lean Road Map
3. Policy Development
4. Lean Implementation Plan
5. Lean Metrics

CERTIFICATE REQUIREMENTS

A 70% or better must be achieved in order to receive a Certificate of Completion.

COURSE OBJECTIVES

Gain a broad perspective of Lean Enterprise concepts and understand the interaction between the Lean elements, rules, and tools.
Understand how Lean concepts can be applied to the different operational departments of a business, why the organization culture must change and why the Lean process must be institutionalized.
Recognize how the application of Lean principles can substantially improve the operating and financial performance of any business.
Understand the need to change and how to recognize and eliminate waste.
Learn how to determine value added, non-valued-added and non-value-added-but-required activities.
Understand why everyone in the organization must participate and how this is accomplished.
Learn the importance of identifying the value stream, how it is mapped and how to identify the areas that require improvement.
Gain a complete understanding of the elements of Flow and Pull and how these are applied.
Learn why the pursuit of perfection is a way of life.
Understand the fundamentals of Standard Work and how these can be used to help eliminate process variation.
Recognize why the limit people and materials rules are important and how they are integrated with the lean tools to eliminate waste.
Understand how to develop a road map and an implementation plan.
Understand Policy Deployment and hwy this is a critical part of any Lean implementation process.
Recognize the fundamental importance of the Kaizen process, how this is used in every aspect of a lean implementation and how it is 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 the concepts of 5S, Single Minute Exchange of Dies (Quick Change), Total Productive Maintenance (TPM), Kanban, Visual Workplace, Error-Proofing, Scheduling.
Understand the role of accounting in the Lean implementation process and how lean metrics must replace traditional metrics. Find out how metrics drive behavior and how cost of quality impacts business performance.
Get an overview of Six-Sigma and how Lean Enterprise and Six-Sigma are complimentary processes that are used to improve business performance.

PDF BROCHURE

Please click here to download the PDF brochure for the Gatlin online courses offered by OCPE.

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WHO SHOULD ATTEND

There are no specific prerequisites for this course. The intended audience is executives, managers, supervisors, professionals and anyone who needs to learn how to substantially improve business performance.

INSTRUCTOR

Brian Furlong is a part-time George Mason University, OCPE, Gatlin instructor and a seasoned, senior executive with 30 years experience in manufacturing and finance. 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 is a passionate advocate of Lean Enterprise, having successfully completed implementation in numerous facilities in the United States, Mexico, Europe, and Asia.

PC REQUIREMENTS

The most commonly used 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 students do not have Excel on their computer, a free download for an Excel viewer will be provided.

FAQ

1. How do I register for a Gatlin online course?

Gatlin does not offer courses directly to the public. It offers courses through George Mason University and other colleges and universities. Please contact our office at 703-993-2113 or click here for more information or to register for a course.

2. How much do Gatlin online courses cost?

To view the prices for all Gatlin courses that are offered by George Mason University, please click here.

3. Why do I have to take Gatlin courses through a participating school?

That is the only way Gatlin Education Services offers its courses. They do not deal directly with the public.

4. Do I have to travel to register for or to attend a Gatlin online course?

All Gatlin courses are delivered entirely online, so you do not have to go to a class or travel to a school. Please contact our office at 703-993-2113 or click here for more information or to register for a course.

5. How long does it take to complete a Gatlin course?

All of our Gatlin courses are asynchronous. You can start and finish the course at your own pace. Most courses are designed to be completed within 180 days. You may request an extension if you think you will need more time to complete a course. Please contact us at 703-993-2113 or click here if you have any questions or if you would like to register for a course.

6. Do I have to buy additional materials?

Please refer to the green Included Materials box located on the upper right hand side of this page. If materials are included in this course, they will be shipped by Gatlin to you via UPS ground service after you have registered for a course.

7. Can I get financial aid for Gatlin courses?

George Mason University offers financial assistance through the Sallie Mae Training Loan Program for qualifying students. Call 703-993-2113 for more information. GES also provides a loan opportunity for students (www.collegeloanapplication.com).

8. What happens when I complete the course?

If you obtain a final passing grade of 70% or greater in a course, we will award you a George Mason University certificate of completion.

9. Who will be my instructor?

Each student is paired up with a George Mason University, OCPE, Gatlin facilitator for one-on-one interaction. The facilitator will be available (by e-mail or by telephone) to answer any questions you may have and to provide feedback on your performance. All of our facilitators are successful working professionals in the fields in which they teach.

10. What are the system requirements in order to take an online course?

Please see the "PC requirements" section listed for individual courses.

11. When can I start the course?

You can register for a course at any time.

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