Learning Outcomes

History of the 5S System

Importance of 5S in the Workplace

Guideline for 5S Initialization

Lesson Summary

This module explains the history of the 5S concept and different frameworks. It also defines each "S" in the 5S model. It also covers the importance of a 5S program along with the benefits. The 6th "S" extension of the basic 5S model to 6S model is also explained. Moreover, the module explains elements which should be planned before the beginning of 5S project, which include team roles, 5S project charter, 5S implementation scope and the summary of the implementation model.

1S Sort - Philosophy and Implementation Methodology

2S Set in Order - Philosophy and Implementation Methodology

The module covers the philosophy and implementation methodology of basic foundations of the 5S implementation program. The basic foundation includes two topics which are 1S (Sort) and 2S (Set in Order). The implementation methodology of 1S and 2S foundations covers the tools required for its implementation, pre-planning activities related to implementation and the necessary and essential steps for implementation. The module covers the implementation of 1S and 2S comprehensively.

3S Shine - Philosophy and Implementation Methodology

4S Standardization - Philosophy and Implementation Methodology

The module covers the philosophy and implementation methodology of middle foundations of the 5S implementation program. The middle foundation includes two topics which are 3S (Shine) and 4S (Standardization). The implementation methodology of 3S and 4S foundations covers the tools required for its implementation, pre-planning activities related to implementation, the necessary and essential steps for its implementation. The modules cover the implementation of 3S and 4S comprehensively.

5S Sustain - Philosophy and Implementation Methodology

Role of Top Management and Gemba Walk

5S, Safety and International Management Systems

The module covers the philosophy and implementation methodology of the last foundation of the 5S implementation program. The last foundation includes topics such as 5S (Sustain), Gemba walk, 5S and ISO systems etc. The implementation methodology of 5S covers the tools required for its implementation, pre-planning activities related to implementation and the necessary and essential steps for implementation. It also covers the top management role and implementation of Gemba walk as well.

Diploma in Lean Manufacturing - First Assessment

Assessment of first chapter of the Lean Manufacturing Diploma level course on 5S Lean Methodology.

Kaizen Introduction and History

Major Kaizen Concepts

This module explains the existing Kaizen philosophy and concepts among successful business and manufacturing organizations in Japan. It also covers the introductory and historical account of Kaizen. It also incorporates the introduction of Kaizen events, types of Kaizen approaches etc. It also explains the steps for a Kaizen Cycle, which is important for Kaizen culture in organizations.

Major Kaizen Systems

Gemba Kaizen

Kaizen Implementation

This module explains the three important topics related to Kaizen and its implementation. These topics are Kaizen systems, Gemba Kaizen and tools and methodologies for Kaizen implementation. Each topic has sufficient information about itself, for instance, Kaizen Systems talk about TQM, JIT, TPM, Policy Deployment, Suggestion system, Group activity etc. Gemba covers 3Ks, Inverted and normal triangle, direct versus indirect earners etc. The last topic includes 7 steps implementation, PQCDSM etc.

Kaizen Events

The Kaizen Story

International Standards and Monitoring of Kaizen Events

In this module, Kaizen Event, Kaizen Story, and Evaluation are taught. Kaizen Event specifies the management of Kaizen events and important elements related to it, which includes pre-event and post-event issues as well and details about event proceeding. Moreover, Kaizen story narrates methods to select a Kaizen theme, situation analysis on current versus future desired state. Lastly, continual vs. continuous improvement is discussed with the coaching of WITs on Kaizen measurement & monitoring.

Diploma in Lean Manufacturing - Second Assessment

Assessment of second chapter of the Lean Manufacturing Diploma level course on Kaizen Lean Methodology.

Context of the Kanban System

Introduction to the Kanban System & Approaches to it

Important Terminologies

This module explains the context the Kanban system, its history, some important concepts as for the context such as push versus pull system, Just in Time (JIT) manufacturing etc. Then module explains some approaches to the Kanban system such as the basic approach which is the three-bin system, the electronic Kanban. Moreover, module also discusses some important terminologies for the Kanban system and its implementation. The terminologies are grouped as practice, tools and the Kanban metrics.

Core Principles and Long-term Thinking

Implementation of the Kanban System

This module explains the core principles and long term thinking for Kanban implementation. Also, it discusses the PDCA in the Lean Kanban, the key considerations, and the conducive environment for implementation. The modules lists and explains all the steps for the implementation of the Kanban system. Moreover, the module goes on explaining types of meeting used by various organization for implementing Kanban, and other recommendations for implementation.

Diploma in Lean Manufacturing - Third Assessment

Assessment of third chapter of the Lean Manufacturing Diploma level course on Kanban Lean Methodology.

Introductory Elements of Lean Quality Control Circles (LQCC)

Roles and Responsibilities in a Quality Circle

This module explains the introduction to Quality Control Circles (QCC). It also presents some important concepts with it. It also covers the comparison of Lean Quality Circles and Quality Control Circles. It also includes discussions on the history of QCC in Japan, basic working framework, the existence of the ICQCC, QCC theme, and then covers various different positions and roles for the QCC to be managed in an organization. Moreover, it also covers different committees for implementing QCC.

Workflow for a Quality Circle

Implementations Aspects of a Quality Circle

This module explains the workflow and implementation aspects of the QCC program. Within the workflow, it covers various different elements of phases and the implementation parts which includes the planning, approval, launching, training, follow-up and validation, implementation, completion, event, signing off and the reward system. Moreover, the module also covers rules for circles' brainstorming, milestones for QCC program, advantages of QCC, launch list, and evaluation criterion.

Diploma in Lean Manufacturing - Fourth Assessment

Assessment of last chapter of the Lean Manufacturing Diploma level course on Quality Circles Lean Participation Model.

Diploma in Lean Manufacturing - Productive Management with Tools - Course Assessment

Learn how the Japanese management concept of ‘lean manufacturing’ can boost production in this free online course.

Diploma in Lean Manufacturing - Productive Management with Fundamental Tools

This diploma course explains how organizations can embrace a lean culture to raise workplace productivity and efficiency. We begin by explaining the business philosophy of ‘Kaizen’ and discuss how organizations can use it to continually improve. We then cover some fundamental ‘lean’ tools like the ‘5 Ss’, housekeeping, ‘Kanban’, scheduling systems and so on. We examine the ‘quality circles’ through which lean cultural change is achieved.

Manufacturing Excellence

Global Environment

Production System

Operation Strategy

The Heart of the TPS - Eliminating Waste

In this module, you will learn about the unique manufacturing system in Toyota and the global impact of the Toyota production system.

Principles of Toyota Way

Culture behind the Toyota way

Long term Philosophy

Create Continuous Flow

In this module, you will learn about the Toyota philosophy and the importance of developing people in an organization.

Pull System

Leveling Workload

Get Quality Right the First Time

Standardization of Tasks

Use of Visual Control

In this module, you will learn about the pioneering effort of Toyota in the pull production system.

Use of Reliable Technology

Role of Leaders in Manufacturing Philosophy

Developing Exceptional Teams

Challenge and Respect Extended Networks

See yourself to Understand the Situation

In this module, you will learn how reliable technology is used in the Toyota production system. You will also learn also learn about the role of leaders in manufacturing philosophy.

Diploma in Toyota Production System - First Assessment

You must score 80% or more to pass this assessment.

Developing Decisions with Consensus

Become a Learning Organization

Become a Learning Organisation - Continuous Improvement

Using Toyota Way for other Organisations (Service and Technical)

Lean Manufacturing

In this module, you will learn how companies become learning organizations.  You will also learn about competitiveness in organizations.

Lean Vs Agile Manufacturing

Sustainable Manufacturing I

Sustainable Manufacturing II

Flexible Manufacturing System

Benchmarking

In this module, you will learn about the similarities between the lean and agile manufacturing approach. You will also learn about green manufacturing.

Cultural Issues in Lean

Overview of Lean Implementation

The Significance of Lead Time

Techniques to Reduce Lead Time

Value Stream Mapping

In this module, you will be introduced to the cultural issues in learn manufacturing and how to implement lean manufacturing.

Kanban Approach

Kanban Calculation I

Kanban Calculation II

Theory of Constraints

Different Business Excellence Models

In this module, you will be introduced to the Kanban approach, calculations in Kanban, theory of constraints and the difference excellence business model.

Diploma in Toyota Production System - Second Assessment

Diploma in Toyota Production System - Final Assessment

Learn about the key principles and practices of the Toyota Production System with this free online course.

Diploma in Toyota Production System

This free online course explains the principles and practices used in the Toyota Production System. You will learn how several manufacturing approaches are effectively used in Toyota. This course will be great interest to operations managers, industrial engineers and professionals who need to know the best practices in operations. Start this course and learn how to ensure no waste and consistently high quality in production processes.