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EDWartens UK

Free course · Manufacturing excellence

Lean Manufacturing, OEE and TPM

The shop-floor half of manufacturing excellence, built in the order a line is actually improved: value and the eight wastes, gemba walks and bottlenecks, lead time and takt time, value stream mapping, flow and cells, pull and kanban sizing, standard work and 5S. Then the two numbers a plant manager is judged on. OEE calculated from a real shift, the six big losses behind it, quick changeover, and total productive maintenance through its eight pillars and twelve implementation steps.

See the modules

Free to learn. Verifiable certificate £19 when you pass the final exam (optional, VAT included).

Level
Beginner
Modules
15
Video
15 hours
Price
Free

Outcome

What you will be able to do

Calculate availability, performance, quality and OEE from one shift of real data and say which factor to attack first; sort a shift of downtime into the six big losses and name the one that is costing most; draw a current-state value stream map with observed data boxes, compute process cycle efficiency and propose a future state; calculate takt time and compare it against measured cycle times to find the constraint; size a kanban loop from demand, replenishment lead time and container size; split a changeover into internal and external elements and plan a SMED exercise; and set up autonomous maintenance on one machine with a rollout plan through the twelve TPM steps.

  • Calculate availability, performance, quality and OEE from one shift of real line data
  • Split a shift of downtime across the six big losses and name the one costing most
  • Draw a current-state value stream map with observed data boxes, then a future state you can reach
  • Calculate takt time and compare it with measured station cycle times to find the constraint
  • Size a kanban loop from demand, replenishment lead time, safety factor and container size
  • Set up autonomous maintenance on one machine and plan a TPM rollout through the twelve steps

Software

None required. A spreadsheet for the OEE, takt time and kanban arithmetic.

Hardware

None. A stopwatch or a phone timer and a notebook for the line observations.

Syllabus

15 modules

Each module has video lessons, notes and a short quiz. The final exam closes the course.

  1. 1Lean: value, the five principles and the eight wastes4 lessons
  2. 2The Toyota Production System and how lean grew4 lessons
  3. 3Seeing the waste: gemba, 5G and bottlenecks4 lessons
  4. 4Lead time, takt time and cycle time2 lessons
  5. 5Value stream mapping3 lessons
  6. 6Continuous flow, cells and single-piece flow3 lessons
  7. 7Pull systems and levelling the workload3 lessons
  8. 8Kanban: how the cards work and how many you need4 lessons
  9. 9Standard work, 5S and visual control4 lessons
  10. 10OEE: what it measures and how to calculate it4 lessons
  11. 11The six big losses and quick changeover3 lessons
  12. 12TPM: what it is and how it grew3 lessons
  13. 13The eight pillars of TPM4 lessons
  14. 14Rolling out TPM and keeping the gains4 lessons
  15. 15Final assessment0 lessons

How it works

How this course works

  1. Watch the video lessonsOne module at a time, at your own pace.
  2. Take the module quizA short quiz at the end of each module shows what stuck.
  3. Keep your notesWrite in My notes beside each module and ask the trainer if you are stuck.
  4. Sit the final examPass it once you have been through the modules.
  5. Certificate, if you want oneOptionalPaid, and only after you pass. Anyone can check it online.

Certificate

An optional certificate when you pass

Learning is free. Pass the final exam and you can have a certificate for £19, including VAT, with a number employers can check online. It records that you completed a free online course; it is not a regulated qualification or a CPD certificate.

  • Your name, the course, its study time and your final exam score
  • A unique certificate number and a QR code to its verification page
  • Issued by Wartens Ltd; add it to your LinkedIn profile in one click
  • Pay now or after you pass: it is issued the moment you pass the final

How the certificate works

Sample certificate for Lean Manufacturing, OEE and TPM

Credits

Who made the lessons

The video lessons belong to their creators. EDWartens wrote the study plan, notes, quizzes and the final exam.

  • IIT Roorkee July 2018

    the NPTEL Toyota Production System lectures: eliminating waste, lean manufacturing, lead time, value stream mapping, continuous flow, pull, levelling, kanban and its calculation, standardisation of task and lean implementation

  • Shakehand with Life

    the TPM series: what TPM is, how it evolved, the eight pillars, what OEE is, how to calculate OEE with a worked example, and the twelve implementation steps

  • Academic Gain Tutorials

    the lean tools glossary and the longer explainers: lean principles, what value is, the eight wastes, 5G, bottleneck analysis, takt time, SMED, poka-yoke, jidoka, the six big losses, 5S, kaizen, PDCA and focused improvement

Questions

About this course

Do I need any software, a licence or a plant of my own?
No. A spreadsheet does all the arithmetic, and a stopwatch or phone timer does the rest. Every practice task has a worked version you can follow on paper if you are not currently on a shop floor.
What do I need to know before starting?
Nothing about lean. If you have done any PLC or SCADA course the OEE modules will feel closer to home, because the downtime and count data usually comes off that layer, but it is not required.
Is this the same as a Lean Six Sigma belt or a JIPM TPM award?
No. This is preparation, not certification. Lean Six Sigma belts are issued by bodies such as ASQ and by training providers under their own schemes, and TPM Excellence Awards are issued by the Japan Institute of Plant Maintenance. This course covers much of the same ground and none of their examinations, and EDWartens does not represent them.
Is the course really free?
Yes. Every module, practice task and assessment. You create an account so your progress is saved and the assessments can be marked. The certificate is the only optional paid item.
What certificate do I get?
An EDWartens Certificate of Completion, issued when you have finished every module and passed the final assessment at 60 per cent, with a verification code anyone can check. It is not a vendor credential and is never described as one.
Who made the video lessons?
The creators named in the Credits block at the foot of this page, on their own YouTube channels. EDWartens did not make the videos and the creators are not affiliated with EDWartens. What EDWartens wrote is the study plan, the notes, the practice tasks and the assessments.
Will this help me move from maintenance into continuous improvement?
That is who it is written for. The engineer who already fixes breakdowns is the one who can tie line data to loss categories, and OEE and TPM literacy is the usual gate for continuous improvement and shift-in-charge roles at auto, FMCG and electronics plants.
How long does it take?
About fifteen to sixteen hours of study across fourteen content modules and a final, which most learners spread over four or five weeks. The practice tasks add more if you do them on a real line, and they are where the value is.

The Professional Module is five live days of Siemens PLC, HMI and SCADA with an instructor, then a resume session and a CPD certificate.

See the Professional Module