Foundations of Lean Manufacturing

By Saideep Rathnam | Indian Institute of Management Bangalore (IIMB)

Learners enrolled: 1096

Overview:

This course aims to equip manufacturing sector professionals, functional heads, supervisors, professors, and students with essential Lean manufacturing tools and concepts. Throughout the course, we explore core Lean principles using practical examples, demonstrating their applicability in diverse manufacturing environments.

Topics covered include observation skills (to observe the source of the issue), the evolution of manufacturing (to grasp the key elements of manufacturing), essential concepts in Lean factory environments (to understand both hard and soft skills needed in a modern manufacturing setting), understanding operations in a lean enterprise, flow management principles (including waste reduction and concepts of material flow), and visual mapping of material flow.

Participants will gain insights into key Lean tools and principles necessary for fostering a mindset shift across organizational structures. By the end of this foundational course, participants will have the terminology, tools, and techniques to analyze and improve operational processes within manufacturing or business contexts.

To ensure engagement and stimulate thought, we utilize a multifaceted approach, including videos, graded and ungraded assignments, discussions, expert insights, and stringent focus on application in a real-world setting. Join us for an exciting journey through a range of ideas, concepts, and case studies, ensuring an enriching experience until the very end. We look forward to embarking on this journey with you.

Objectives:

1. To Transform Students of Engineering and Management as Manufacturing Change Leaders

2. To develop engineering college faculty as lean experts and lean consultants

3. To Equip Sector Professionals, Functional Heads and Supervisors with essential tools and concepts of Lean manufacturing

4. To Enable Participants to Gain Insights into Key Lean Tools and Principles Necessary for Fostering a Lean Mindset Shift across Organizational Structures

Summary

Course Status :	Completed
Course Type :	Core
Language for course content :	English
Duration :	6 weeks
Category :	Management Studies
Credit Points :	3
Level :	Postgraduate
Start Date :	26 Jul 2024
End Date :	31 Oct 2024
Enrollment Ends :	31 Aug 2024
Exam Date :	15 Dec 2024 IST
Shift :	2

Note: This exam date is subject to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1: Observation Skills
Week 2: Evolution of Manufacturing
Week 3: Essential Concepts in Factory
Week 4: Understanding Lean Operations
Week 5: Introduction to Flow Management System
Week 6: Visual Mapping of Material Flow

Syllabus page

Exam Schedule

Books and references

"• Flow Management Tools and Methods for Manufacturing / Dr. Abhilash Pathania

• Simplified lean manufacture: Elements, rules, tools, and implementation / N. Gopala Krishnan

• Lean supply chain management essentials: a framework for materials managers / Bill Kerber and Brian J Dreckshage

• Lessons in lean management: 53 ideas to transform services / by Debashis Sarkar.

• Life on the line in contemporary manufacturing: The workplace experience of lean production and the Japanese model / by Risk Delbridge

• Lean administration: case studies in leadership and improvement. / Association for Manufacturing Excellence

• Toyota Production System: Beyond Large-Scale Production / Taiichi Ohno

• My Life and Work / Henry Ford

• The Machine That Changed the World / James P. Womack, Daniel T. Jones, and Daniel Roos

• Learning to See: Value Stream Mapping to Add Value and Eliminate Muda / Mike Rother and John Shook

• Lean Production Simplified / Pascal Dennis

• Complete lean enterprise: Value stream mapping for administrative and office processes / by Beau Keyte, Drew Locher"

Instructor bio

Saideep Rathnam

Indian Institute of Management Bangalore (IIMB)

"Mr. Saideep Rathnam currently occupies the position of Chief Operating Officer at Mizuho India Japan Study Centre . He has completed his Bachelor’s Degree in Science from Bangalore University and holds Bachelor of Engineering [Electronics & Communication] from Indian Institute of Science, Bangalore. He is alumnus of IIMB, PGP batch of 1978-80. He is also a Certified Chartered Management Accountant [CMA], UK.

He has over 47 years of rich experience in the Industry and Academia. He started his career in Hindustan Aeronautics Ltd. and served for 20+ years in various capacities and functions, including as the Resident Manager at London [UK], primarily working with British Aerospace, UK. He has also worked with Anand Automotive Ltd., an auto-component giant in India for 18+ years in various capacities, including as President (Manufacturing Excellence).

In the Academic Area, he has worked as the Dean of Anand University, a Corporate University, responsible for leadership and operational transformation. As a Consultant, he has also helped companies in the fields of management of change and innovation. He has worked with Industry bodies and has been driving the Visionary Leaders for Manufacturing (VLFM) program as a Senior Advisory Committee Member of CII.

Mr. Saideep Rathnam has written a book ‘Creating Next Generation Manufacturing Change Leaders’, documenting the unique approach for creating industry-ready engineers trained in the new manufacturing paradigm of flow-oriented manufacturing."

Kalpana Narain

Kalpana comes with over 35 years of corporate experience spread across leadership development for the manufacturing sector and in investment banking. Over these years she has worked with both domestic and international corporates, governments and academic institutions. In addition, Kalpana has authored several case studies on manufacturing excellence, organization transformation and breakthrough improvements in manufacturing systems.

Since 2012, Kalpana has been an independent consultant. She is a level 1 ACC coach and works with teams for leadership development. She curates and delivers leadership development programs for Indian manufacturing companies, guides the teams in identifying breakthrough projects and designing delivery roadmaps. These projects cut across the range of breakthrough improvements in manufacturing excellence or product enhancement, new product development or new market explorations.

In 2003, Kalpana was attached with Padma Shri Prof Shoji Shiba, Professor Emeritus, Massachusetts Institute of Technology (MIT) for working developing leadership skills in India’s manufacturing sector. In 2006, she took charge of an industry-academia committee set up by JICA-CII for design, development and delivery of the Visionary Leaders for Manufacturing program (VLFM). Kalpana played a key role in the development, design and implementation of this program. Focused on skilling senior managers and CEOs of India’s manufacturing sector, VLFM continues to be a flagship program of the Governments of India and Japan. Much of her work has been delivered for JICA, Confederation of Indian Industry, USAID and other development initiatives.

Course certificate

Enrolling and learning from the course is free. However, if you wish to obtain a certificate, you must register and take the proctored exam in person at one of the designated exam centre’s. The registration URL will be announced when the registration form is open. To obtain the certification, you need to fill out the online registration form and pay the exam fee. More details will be provided when the exam registration form is published, including any potential changes. For further information on the exam locations and the conditions associated with filling out the form, please refer to the form.

Grading Policy:

Assessment Type	Weightage
Mid-term & End-term	25%
Final Exam	75%

Certificate Eligibility:

40% marks and above in the internal assessment(mid-term & end-term)
40% marks and above in the final proctored exam

Score	Type of Certificate
>=90	Gold
75 - 89	Silver
70 - 74	Bronze
40 - 70	Successfully Completed
<40	No Certificate

Sample Certificate:

Disclaimer: In order to be eligible for the certificate, you must register for enrolment and exams using the same email ID. If different email IDs are used, you will not be considered eligible for the certificate.

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