Essential Lean Manufacturing For Management Consultants

A practical guide on how to improve production and operations in a firm and analyze potential savings in Excel

What you'll learn
Analyze production process
Apply lean manufacturing techniques in practice
Improve production process – make it faster, cheaper and at higher quality
Calculate in Excel the potential impact of proposed changes
Apply improvement techniques to other fields and industries
Identify and remove bottlenecks
Manage projects using critical chain methods
Requirements
Basic or intermediate Excel
Basic knowledge of economics or finance
Description
What is the aim of this course?    This course will help you drastically improve your knowledge and skills in optimizing the production, and operations of any company through a series of practical cases. It is designed for people who want to become consultants, business analysts or have to run and optimize production on a daily basis. In the course you will learn 3 things:    How to understand any production or operational activities   How to optimize the production and operations in order to get more things done, cheaper at higher quality with fewer resources using elements from lean manufacturing, theory constraints Where to look for savings and improvements, how to calculate potential savings in Excel and implement them   I will concentrate here on lean manufacturing techniques as well as things related to the theory of constraints (removing bottlenecks and critical chain).    This course is based on my 15 years of experience as a consultant in top consulting firms and as a Board Member responsible for strategy, performance improvement, and turn-arounds in the biggest firms from Retail, FMCG, SMG, B2B, and services sectors that I worked for. I have carried or supervised over 90 different performance improvement projects in different industries that generated in total 2 billion of additional EBITDA. On the basis of what you will find in this course, I have trained in person over 100 consultants, business analysts, and managers who now are Partners in PE and VC funds, Investment Directors and Business Analysts in PE and VC, Operational Directors, COO, CRO, CEO, Directors in Consulting Companies, Board Members, etc. On top of that my courses on Udemy were already taken by more than 110 000 students including people working in EY, Walmart, Booz Allen Hamilton, Adidas, Naspers, Alvarez & Marsal, PwC, Dell, Walgreens, Orange, and many others.I teach through case studies, so you will have a lot of lectures showing examples of analyses, tools that we use. To every lecture, you will find attached (in additional resources) the Excels as well as additional presentations, materials shown in the lectures so as a part of this course you will also get a library of ready-made analyses that can, with certain modification, be applied by you or your team in your work.   Why have I decided to create this course?    Most consultants and business analysts are terrible at organizing operational issues. They treat the operations, especially production, as a black box and try to avoid it at any cost. Technical things overwhelm them and they shy away from them. This approach is not the right one as you find elements that resemble production everywhere. In hospitals, most procedures performed are very similar to production issues. The same goes for running a call center, a chain of restaurants, a logistic company, or a firm delivering specialized services. Everywhere you have operations that you can optimize by using techniques that I will show in this course.  Production influence heavily other areas especially sales and marketing. Therefore, it is a good idea to have at least a general knowledge of production. The funny thing is that to be good at production you do not even have to be technical at all. I have not finished any technical school and I am pretty good in finding significant improvements in production. One of the best Production Directors I know has finished Pedagogical Studies.    To sum it up, I believe that if you want to build or to find improvements in any business you should master techniques related to optimizing production. That is why I highly recommend this course not only to consultants or business analysts that have to advise their customers but also to owners, founders of businesses as well as production directors.    In what way will you benefit from this course?   The course is a practical, step-by-step guide loaded with tones of analyses, tricks, hints that will significantly improve the speed with which you find and analyze production. There is little theory – mainly examples, a lot of tips from my own experience as well as other notable examples worth mentioning. Our intention is that thanks to the course you will know:    How to understand the production    How to optimize it    Where to look for savings and improvement in production    How to calculate the impact of proposed changes in Excel    You can also ask me any question either through the discussion mode or by messaging me directly.   How the course is organized?    The course is divided currently into the following sections:    Introduction. We begin with a little intro into the course as well as some general info on production    Basic methods of improving production. In the second section, I will discuss the basic techniques that you can use to optimize your business. Here you will find the potential low-hanging fruits. Here I will show you basic lean manufacturing methods as well as elements of the theory of constraints. You will also see how to calculate potential savings in Excel    Continuous Flow. The ideal in production is the so-called continuous flow in which goes smoothly and fast. Products are being produced fast and cheaply. In this section, I will tell you how to achieve it. This is one of the pivotal elements of lean manufacturing    Advanced methods of improving production. In this section, I will continue with the more advanced ways in which you can improve your production such as SMED, TPM, Automation, Critical Chain    Capacity management. Apart from optimizing the production you have to think strategically and know when you have to add a new capacity/factory. In this section, I will show you how you can do that    Production planning. Production planning is the brain of production. If you get this wrong the other things won’t matter. In this section, I will show you some ways in which you can analyze and improve production planning   A case study in Optimization of in-store processes using Lean Manufacturing. In this section, I will show you how you can use lean manufacturing techniques to optimize processes in stores.You will be able also to download many additional resources   Excels with analyses shown in the course   Presentation of slides shown in the course   Links to additional presentations and movies    Links to books worth readingAt the end of my course, students will be able to…Analyze production processImprove production process – make it faster, cheaper, and at higher qualityCalculate in Excel the potential impact of proposed changesApply improvement techniques to other fields and industriesWho should take this course? Who should not?ConsultantsProduction DirectorsBusiness analystsSmall and medium business ownersStartups foundersControllersWhat will students need to know or do before starting this course?Basic or intermediate ExcelBasic knowledge of economics or finance

Overview

Section 1: Introduction

Lecture 1 Introduction

Lecture 2 About me

Lecture 3 Why knowing production issues is important?

Lecture 4 What subjects we will talk about?

Lecture 5 How to deal with Blurry image

Lecture 6 How to reach additional resources

Section 2: Basic methods of improving production

Lecture 7 Introduction to improving production

Lecture 8 Different types of waste

Lecture 9 5 Whys

Lecture 10 OEE

Lecture 11 Removing bottlenecks

Lecture 12 Removing bottlenecks – Example from production – Case Introduction

Lecture 13 What the production capacity depends on?

Lecture 14 How to calculate the capacity for the whole month

Lecture 15 Removing bottlenecks – Example from production – Scenarios – Part 1

Lecture 16 Removing bottlenecks – Example from production – Scenarios – Part 2

Lecture 17 Removing bottlenecks – Example from production – Available Data

Lecture 18 Removing bottlenecks in Production – Solution

Lecture 19 Removing bottlenecks – Example from production – Graphs

Lecture 20 Standarization

Lecture 21 Standarization - calculation in Excel

Lecture 22 5S - Introduction

Lecture 23 5S - calculation in Excel

Lecture 24 Get rid of unused things - office

Lecture 25 Kanban introduction

Lecture 26 Kanban in Excel

Lecture 27 Kanban for services - examples

Lecture 28 Zero defect rule

Lecture 29 Universal worker

Lecture 30 Universal worker - Excel

Lecture 31 1 worker 2 machines

Lecture 32 1 worker 2 machines - Excel

Section 3: Continuous Flow

Lecture 33 Continuous Flow - Introduction

Lecture 34 How NOT to make continuous flow – sandwich factory

Lecture 35 How to make continuous flow – sandwich factory no kanban

Lecture 36 How to make continuous flow – sandwich factory with kanban

Lecture 37 Continuous flow in services

Lecture 38 Smart batching

Section 4: Advanced methods of improving production

Lecture 39 OLE vs OEE

Lecture 40 Waste analysis

Lecture 41 Decrease waste – Case Introduction – Plywood

Lecture 42 Decrease waste – Data Available

Lecture 43 Decrease waste – Case Study – Solution

Lecture 44 Set-ups

Lecture 45 SMED - Introduction

Lecture 46 SMED - example from fish industry - case

Lecture 47 SMED - example from fish industry - solution

Lecture 48 TPM

Lecture 49 Automation - Introduction

Lecture 50 Critical chain

Section 5: Capacity management

Lecture 51 Why you need to do capacity management?

Lecture 52 How to manage capacity?

Lecture 53 Supplier catchment area

Lecture 54 Customer catchment area

Lecture 55 Catchment area / reach analysis - B2B

Section 6: Production planning.

Lecture 56 Optimal production batch analysis - FMCG

Lecture 57 2-stage production planning

Section 7: Case study - Optimizing processess in the store using Lean manufacturing

Lecture 58 Optimization of in-store processes - Introduction

Lecture 59 Workshop - Introduction

Lecture 60 Workshop – the scope of the project

Lecture 61 Workshop – Tools overview

Lecture 62 Lean manufacturing - introduction

Lecture 63 Theory of constraints - introduction

Lecture 64 Queuing problem - introduction

Lecture 65 OEE - introduction

Lecture 66 Workshop – defining metrics and cost drivers

Lecture 67 Workshop – optimizing 1 process

Lecture 68 Workshop – optimizing 1 process - Excel file

Lecture 69 Workshop – timeline of the project

Lecture 70 Introduction to in-store process optimization case

Lecture 71 The store and the processes

Lecture 72 Price Change

Lecture 73 Price Change - calculation in Excel

Lecture 74 Shelf replenishment

Lecture 75 Shelf replenishment - calculation in Excel

Lecture 76 Advising customers - Introduction

Lecture 77 Advising customers - General solution

Lecture 78 Advising customers - Details and results

Lecture 79 Advising customers - calculation in Excel

Lecture 80 Cash till and info point

Lecture 81 Other potential improvements

Lecture 82 Process cost estimation by groups

Lecture 83 Summary of all costs and savings

Section 8: Conclusions

Lecture 84 Bonus Lecture

Management Consultants,Production Directors and Managers,Business Analysts,Small and medium business owners ,Startups founders,Controllers