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THE STEP-BY-STEP GUIDE TO BUILDING THE PERFECT VALUE STREAM...

THE ONE WEBSITE FOR LEAN INDUSTRIAL ENGINEERING AND MIXED MODEL MANUFACTURING…THE SOURCE OF 80%+ OF THE BENEFITS OF LEAN MANUFACTURING!

THE STUDIO WILL HELP YOU TO:

Learn and Apply

the foundation tools and methods of Lean, Lean Industrial Engineering. Without this foundation, all other Lean tools (including trying to build a Lean culture) will be ineffective and unsustainable.

Master the Disciplines

of Mixed Model Line Design, Mixed Model Material Management, and Lean Simulation Modeling. Complete a course of study in each of these disciplines and earn a Certificate of Completion.

Build Dynamic Models

of your Value Stream Designs. The worst time to make changes is when your design is already implemented. Mixed Modeling and Discrete-Event Simulation go hand-in-hand to ensure a bullet-proof result.

Dive Deep

into specialized Mixed Model topics that are challenging and seldom-discussed. Study mini-courses on product sequencing, operator flexing, elimination of part selection time, and many other issues.

Get Help

in a variety of ways. Attend weekly public "Ask Me Anything" sessions, schedule one-on-one private talks with Studio Experts, or even launch full implementation programs with our coaching help.

Sustain Your Changes

by following a proven and repeatable methodology. You need to make Mixed Model Manufacturing the standard approach to process improvement. This is how the "big boys" do it, including Toyota.

OUTCOME-FOCUSED MEMBERSHIP SITE

  • Outcome 1: Earn a Certificate in Mixed Model Skills

    Pursue a structured course of study in Mixed Model Line Design, Mixed Model Material Management, and Mixed Model Simulation Modeling. Pass a comprehensive exam in each subject and earn a formal Certificate.

  • Outcome 2: Gain Hands-On Expertise in Discrete-Event Simulation Modeling

    Whoever builds the best models wins. The best way to test your Value Stream designs before you physically implement them is through "discrete-event simulation modeling". We've made it easy with the Lean Design Simulator, included in your Professional membership subscription.

  • Outcome 3: Connect with the Community of Lean Design Experts

    Participate in private and public sessions with the Lean Design Studio coaches, other Studio member experts, and even invited guests from Toyota and other leading Mixed Model companies. Post questions and schedule chat sessions at any time!

  • Outcome 4: Partner with the Studio on Design Projects

    Get access to our detailed implementation Roadmaps for both Kaizen and Kaikaku-scale improvement projects. Partner with Lean Design Studio coaches at whatever level of help you need to speed up the rate of improvement and avoid costly mistakes.

  • Outcome 5: Lead Your Organization in Building a True Lean Culture

    Mixed Model Manufacturing represents the most fundamental and important aspect of Lean Manufacturing. None of the other tools and methods of Lean are possible without this foundation, and you will find it in place at all Lean organizations. You can be the one to lead or sustain this discipline and practice.

VIDEO: INTRODUCTION TO MIXED MODEL MANUFACTURING

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THE MAIN SECTIONS OF THE LEAN DESIGN STUDIO

The START section of the Lean Design Studio is intended for people just getting started with Mixed Model Manufacturing, or want to get a quick refresher on the subject. Currently there are six courses (multi-lesson presentations) on  Flow Manufacturing, Lean Process Design, and Lean Material Management. Focused videos on specialized topics like Kanban, Lean History, and the Toyota Production System can also be found here. Finally, we have included some tools: the Lean Benefits Calculator, and a tools to estimate the Total Cost of Procurement. All of these resources are included in the Free Membership Level.

The EXPLORE area of the Lean Design Studio is the home of the full Mixed Model Line Design and Mixed Model Material Management courses. There are the same courses that we have been teaching at Toyota since 2012. Another essential course in this section is a Crash Course in Simulation Modeling. The Studio includes a simulation modeling system, and this course is the best way to get started. The EXPLORE section also includes over 20 short videos on specialized advanced topics. All of this material is included in the Student and Professional Membership levels.

The LEARN area of the Studio is where we host the Certification Tracks for Line Design, Material Management and Simulation Modeling. To earn a formal certification in each subject, you will need to complete a series of courses, pass an extensive final exam, and also completed a project. Ideally the project would yield real benefits in your company (and we will help you define the project). If you don’t have a “real” project available, the Studio will provide you with one. Your project will also benefit from live feedback from the Lean Design Studio staff. 

The SIMULATE area of the Lean Design Studio is where you will find the Lean Design Simulator, related training videos, and a complete User Guide. The Simulator is a discrete-event simulation engine that runs in a Chrome or FireFox browser. The model building and the model analysis is all done using a spreadsheet (Excel or Google Sheets). Simulation modeling is a key skill that most Lean Specialists don’t have, but should. The Lean Design Simulator makes it possible, and is included in the Student and Professional Membership levels, as well as all higher levels.

The STREAM program combines two elements of a Mixed Model Manufacturing implementation program: 1) the need to train your team in the methodology and 2) the desirability to follow a proven implementation Roadmap. In the STREAM program, focused on Workflow Design, your team will complete the online training course, and immediately implement that lesson on a real and substantial improvement project. By the end of the course the team will have not only completed the course lessons, but they will have also launched a Line Design project. Lean Design Studio experts will guide your team remotely for each step of the way. We expect STREAM programs to achieve a 10 to 1 Return On Investment.

The LINKED Material Management implementation program is structured like the STREAM program, but with a focus on the design and implementation of a material delivery system based on Lean principles. Like the STREAM program, the staff from the Lean Design Studio will be a part of your team, and lead weekly review meetings, and respond to questions via the online forum.

WHO HAVE WE TRAINED AND COACHED?

This is a partial list of the companies that we have worked with on Mixed Model Manufacturing (MMM) improvement projects, or have trained in MMM in our public and private workshops, including those hosted by Toyota Material Handling.

Advanced Lighting Technology
B/E Aerospace
Baker Hughes
Ball Aerospace
The Boeing Group
Borg Warner
CCX Corporation
CNH Reman
Cummins
Daimler Trucks North America
Emerson Electric
Fender Musical Instruments
Fox Racing Shox
GE
Hayward Industries
Hitachi
IBM
Ingersoll Rand
Jabil
John Deere
The Linde Group
MacLean Power Systems
Mattel

Medtronic
Panduit
Parker Hanifin
Performance Composites
Performance Excellence Pathways
Performance Fibers
Plexus
Polaris
Quality Electrodynamics
RBC / Aircraft Products
Rolls-Royce Corporation
S&C Electric Company
Schutt Sports
Spellman High Voltage
Spirit AeroSystems
Stanley Black & Decker
Stant Corporation
Superior Industries
Thermo King
Toyota
United Performance Metals
US Endoscopy
Volkswagen

FEATURES AND PRICING TABLE

FEATURE FREE MEMBERSHIP PROFESSIONAL LEVEL

Courses

Mixed Model Line Design Complete Course
Mixed Model Material Management Complete Course
Crash Course in Simulation Modeling

Introduction to Mixed Model Line Design
Introduction to Flow Manufacturing
Introduction to Material Management
Simulation Modeling for Lean Professionals

Certificate Learning Tracks

Mixed Model Line Design Certificate
Mixed Model Material Management Certificate
Mixed Model Simulation Modeling Certificate

Simulation Modeling Software

Lean Design Simulator Engine
Lean Design Simulator Training Videos

Additional Mixed Model Training

Lean Basics Video Series (START)
Advanced Mixed Model Line Design Methods (EXPLORE)
Advanced Material Flow Methods
Mixed Model Simulation Tips

Other Mixed Model Tools

Lean Benefits Calculator
Lean Design Studio User Forum
Download The Complete Guide to Mixed Model Line Design Sourcebook

PARTICIPATION LEVELS AND ENROLLMENT

Free Membership

$0 / month
  • Access to select online courses: Intro to Line Design, Intro to Material Management, Intro to Flow Manufacturing, Crash Course in Simulation Modeling
  • Full access to the Lean Basics area of the Studio.
  • Download a copy of The Complete Guide to Mixed Model Line Design
  • Post questions and comments in the online Forum
  • No credit card required

Professional Level

$47 / month
  • Yearly Membership Available ($499). One month free!
  • Access to all online courses: Line Design, Material Management, Simulation Modeling
  • Access to the Lean Design Simulator and support documentation and videos
  • Access to the Lean Basics and Advanced Topics sections of the Studio.
  • Download a copy of The Complete Guide to Mixed Model Line Design
  • 24/7 support via an online Forum
  • Yearly Membership eligible for VIP Bonus programs, including Toyota tours.

WHO WE ARE

Leonardo Group Americas Logo

Leonardo Group Americas was founded by Richard Rahn and Gerard Leone, industry vets with 25+ years of Lean experience. They are the authors of eight books on Lean subjects, including The Complete Guide to Mixed Model Line Design. Since 2011 they have partnered with Toyota Material Handling to present workshops on the subjects of Mixed Model Line Design and Mixed Model Material Management to thousands of Industrial Engineers and Lean Professionals. A sister organization in Munich, Germany provides the same approach to Lean in the European Union.

The Lean Design Studio is the culmination of the tools and the methodologies that these two experts have developed over their decades in industry. The Lean Design Studio combines online versions of our core training courses with a newly developed simulation tool, designed specifically for Mixed Model Manufacturing applications.

Any Questions? Schedule a Call!