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.
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
The Boeing Group
Daimler Trucks North America
Fender Musical Instruments
Fox Racing Shox
The Linde Group
MacLean Power Systems
Performance Excellence Pathways
RBC / Aircraft Products
S&C Electric Company
Spellman High Voltage
Stanley Black & Decker
United Performance Metals
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
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.