Manufacturing excellence · Free online course

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.

  • 15 modules
  • 10h 47m of video
  • Beginner
  • English
  • ₹0, free
Lean Manufacturing, OEE and TPM course cover

₹0Free for good

Worth ₹5,999 by length and depth against classroom training. It has always been free; that is not a former price.

No card. Checkout takes a minute and gives you a receipt.

Overview

About Lean Manufacturing, OEE and TPM

Learn lean manufacturing on the shop floor: calculate OEE, map a value stream, size a kanban loop and set up TPM.

Lean Manufacturing, OEE and TPM is a free, self-paced online course from EDWartens for production, industrial and maintenance engineers. It has 15 modules and 10h 47m of video lessons by IIT Roorkee July 2018, Shakehand with Life, Academic Gain Tutorials, with written notes and worked problems, a practical project with a document pack and a 15-question final assessment (pass mark 60%). Learning is free with an account; an optional certificate with a public verification code is issued when you pass. Last updated 27 September 2026.

Who it is for: Production, industrial and maintenance engineers

This course includes

  • 10h 47m of video lessons
  • 15 modules with written notes and diagrams
  • One final assessment: 15 questions, pass mark 60%
  • Ask-an-engineer support from practising engineers
  • Lifetime access, the course does not expire
  • Optional verifiable certificate when you finish
  1. Step 1 of 3

    Learn the 15 modules

    10h 47m of video lessons, written notes and a practice task per module, at your own pace.

  2. Step 2 of 3

    Pass the final assessment

    15 questions drawn from every module, pass mark 60%, 3 attempts.

  3. Step 3 of 3

    Take the certificate, if you want it

    Optional, paid once, only if you choose it. The course stays free either way.

    See the certificate and its price

A look inside

Lean Manufacturing, OEE and TPM: Syllabus at a glance
Syllabus at a glance
Lean Manufacturing, OEE and TPM: What you will be able to do
What you will be able to do
Lean Manufacturing, OEE and TPM: Tools and credits
Tools and credits

From the lessons

  • Introduction to Lean Management (Definition, Lean Principles & Benefits)

    Lean: value, the five principles and the eight wastes

    by Academic Gain Tutorials

  • The Heart of the TPS : Eliminating Waste

    Seeing the waste: gemba, 5G and bottlenecks

    by IIT Roorkee July 2018

  • Value Stream Mapping

    Value stream mapping

    by IIT Roorkee July 2018

  • Pull System

    Pull systems and levelling the workload

    by IIT Roorkee July 2018

  • Standardization of Task

    Standard work, 5S and visual control

    by IIT Roorkee July 2018

  • Six Big Losses - Definition, Method, Benefits Explained (Lean Manufacturing Tools)

    The six big losses and quick changeover

    by Academic Gain Tutorials

Lesson frames belong to the creators named in the Credits and are shown from YouTube.

What you learn

What you will be able to do

By the end you will be able to:

  • Calculate availability, performance, quality and OEE from a shift of data
  • Sort downtime into the six big losses
  • Draw a current-state value stream map and propose a future state
  • Calculate takt time and size a kanban loop
  • Plan a quick changeover exercise using SMED

How it works

How this course works

  1. Watch the lessons

    Short video lessons, one module at a time, at your own pace.

  2. Read the notes

    Open the Reading tab for the written notes and diagrams of the module.

  3. Check yourself

    Answer the questions to see what stuck before you move on.

  4. Final assessment

    Pass the final once you have been through the modules.

  5. Certificate, if you want oneOptional

    Optional, with a page anyone can use to verify it.

Syllabus

Course content, module by module

In order, at whatever pace suits you. Each module ends with a practice task that builds on the last.

Modules
15
Video lessons
49
Of video
10h 47m
Final questions
15
  1. 01

    Lean: value, the five principles and the eight wastes

    4 lessons · 34m
  2. 02

    The Toyota Production System and how lean grew

    4 lessons · 41m
  3. 03

    Seeing the waste: gemba, 5G and bottlenecks

    4 lessons · 39m
  4. 04

    Lead time, takt time and cycle time

    2 lessons · 44m
  5. 05

    Value stream mapping

    3 lessons · 43m
  6. 06

    Continuous flow, cells and single-piece flow

    3 lessons · 37m
  7. 07

    Pull systems and levelling the workload

    3 lessons · 1h 11m
  8. 08

    Kanban: how the cards work and how many you need

    4 lessons · 1h 9m
  9. Final assessment · 15 questions, pass mark 60%

Project

The course project

Optional practice that ends in the kind of job the course prepares you for, with the documents that go with it.

About 14 hours

OEE from 59 to 70 % on a 12,000 bph bottling line: charter, Pareto, SMED and autonomous maintenance

Run an OEE improvement project on a PET bottling line at a beverage plant. Compute the baseline availability, performance and quality from a month of shift data. Map the value stream and the downtime by cause, and rank the six big losses. Cut the changeover with a SMED study. Put autonomous maintenance on the filler, with a standard the operators can follow. Audit 5S, and prove the new OEE with the same arithmetic. You deliver your own charter, downtime register, loss report and standard work. The sample pack shows what a lean consultant leaves behind at a plant.

This project at a glance
  1. 7documents in the pack
  2. 8steps to follow
  3. 6things to hand in
  4. 14 hof work, at your pace

Sample document pack, 7 documents, filled in for the scenario

  • PlanProject Charter: OEE Improvement, PET Line 2, Silverline Beverages Dubai
  • RegisterValue Stream Map Data and Downtime Register: Line 2, August 2026
  • ReportLoss Analysis and SMED Study Report, with the October 2026 Result
  • ProcedureStandards: Filler Autonomous-Maintenance CIL Standard and Changeover Standard Work
  • Register5S Audit: Line 2 Areas, Audit 1 (10-Sep-2026) and Audit 2 (28-Oct-2026)
  • RegisterAbnormality Tag Register: Filler and Blow-Moulder Initial Clean, 21-Sep-2026
  • Training recordTraining Record: Operators, Technicians and Supervisors, Line 2

Read inside the course and download as a workbook. The project is optional practice, marked when you submit it; the certificate needs only the modules and the final assessment.

Tools

Software, hardware and lessons

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.

Who it is for

Beginner. No prior lean, quality or maintenance training is assumed. It sits naturally after any PLC or SCADA course, because the loss data OEE is built from comes off that layer.

Video lessons by

  • IIT Roorkee July 2018
  • Shakehand with Life
  • Academic Gain Tutorials

Independent creators, credited in full under Credits.

Software you need

What to download, where from, what it costs and how to install it. Every link goes to the maker's own site, never a mirror.

Nothing to install

A spreadsheet is enough for the OEE, takt time and kanban arithmetic.

Optional

Useful, not needed to finish the course.

  1. 01

    LibreOffice

    The Document Foundation

    Free
    Runs on
    Windows 10 or 11, macOS 11 or newer (Intel or Apple silicon), Linux
    Account
    None needed
    Size
    up to 1.5 GB of disk space on Windows

    LibreOffice is free, open-source software under the Mozilla Public License 2.0, for any use including business. Calc is its spreadsheet.

    Official download pagelibreoffice.org

Checked against each maker's own page on 27 September 2026. Trial lengths and editions change; the maker's page is the final word.

What you walk away with

Your certificate for Lean Manufacturing, OEE and TPM

Finish the course, pass the final, and this is the document with your name on it.

Sample Wartens Certificate of Completion for Lean Manufacturing, OEE and TPM, issued through the EDWartens training portal
Sample. The issued certificate carries your name, your final score, a unique certificate ID and its own QR code.
  • Verifiable by anyone

  • Adds to LinkedIn in one click

  • QR code on the certificate

  • Names what you can do

  • A permanent link

  • Earned, not attended

Learning is free. The certificate is optional.

Add it now and pay only when you have finished the course, or come back for it later. One-off, US$23.99, with a receipt.

Issued by Wartens Ltd (England and Wales, company no. 15262249) through the EDWartens training portal, as a Certificate of Completion for this self-paced course. Sold in India by Wartens Automation Private Limited. It is not a vendor certification, a university award or a CPD-accredited activity, and it does not certify competence on live equipment. Delivered electronically; see the refund policy.

Why learn with EDWartens

What you get with this course.

  • Free from the first lesson to the final assessment.
  • Video lessons with written notes and a project.
  • An optional certificate that anyone can verify online.

FAQ

Common questions

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 Lean Manufacturing, OEE and TPM 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 does the Lean Manufacturing, OEE and TPM course give?

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 in the Lean Manufacturing, OEE and TPM course?

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 the Lean Manufacturing, OEE and TPM course 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.

Is the Lean Manufacturing, OEE and TPM course free in India, and what does the certificate cost?

Yes. Learning costs ₹0 in India: every module, the written notes, the practice tasks and the final assessment, with no card and no trial period. The only paid item is the optional EDWartens Certificate of Completion, ₹499 including GST for this beginner course, paid in rupees through Razorpay, and only if you want it after passing the final assessment.

All course facts
Price
₹0, free for good. No trial, no card. Comparable classroom training of this length costs about ₹5,999.
Who it is for
Production, industrial and maintenance engineers
Format
15 self-paced modules, 10h 47m of video, written notes, a practice task per module and one final assessment.
Level
Beginner. Beginner. No prior lean, quality or maintenance training is assumed. It sits naturally after any PLC or SCADA course, because the loss data OEE is built from comes off that layer.
Brand
Vendor-neutral
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.
Certificate
Optional EDWartens Certificate of Completion, ₹499 inclusive of GST for learners in India, verifiable by code. Not a vendor credential.
Video lessons by
IIT Roorkee July 2018, Shakehand with Life, Academic Gain Tutorials (independent creators, credited below)
Language
English
Last updated
27 September 2026

More free courses: Free maintenance and reliability courses · Free Six Sigma and quality courses · Free project management courses

Classroom course, Bangalore

PLC training in Bangalore

The Automation Engineer Program (AEP) is our classroom course in PLC programming and industrial automation, taught in person at our Electronic City centre.

Credits

Who made the video lessons

The video lessons in this course were created by the people below, not by EDWartens. Every lesson streams from its creator's own YouTube channel; EDWartens neither hosts nor sells that footage, and the creators are not affiliated with EDWartens and do not endorse this course. What EDWartens wrote is the study plan, the notes, the practice tasks and the assessments.

  • IIT Roorkee July 2018the 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 Lifethe 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 Tutorialsthe 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

If you are one of these creators and would like a lesson removed or credited differently, write to info@wartens.com.