Manufacturing excellence · Free · ₹0
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.
Inside the course
From the lessons
Lean: value, the five principles and the eight wastes
Academic Gain Tutorials
Seeing the waste: gemba, 5G and bottlenecks
IIT Roorkee July 2018
Value stream mapping
IIT Roorkee July 2018
Pull systems and levelling the workload
IIT Roorkee July 2018
Standard work, 5S and visual control
IIT Roorkee July 2018
The six big losses and quick changeover
Academic Gain Tutorials
Lesson frames belong to the creators named in the Credits below and are shown from YouTube.
What you will learn
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
Course content
15 modules · 49 lessons · 10h 47m
In order, at whatever pace suits you. Each module ends with a practice task that builds on the last, and a short quiz.
- 01Lean: value, the five principles and the eight wastes4 lessons34m
- 02The Toyota Production System and how lean grew4 lessons41m
- 03Seeing the waste: gemba, 5G and bottlenecks4 lessons39m
- 04Lead time, takt time and cycle time2 lessons44m
- 05Value stream mapping3 lessons43m
- 06Continuous flow, cells and single-piece flow3 lessons37m
- 07Pull systems and levelling the workload3 lessons1h 11m
- 08Kanban: how the cards work and how many you need4 lessons1h 9m
- 09Standard work, 5S and visual control4 lessons41m
- 10OEE: what it measures and how to calculate it4 lessons28m
- 11The six big losses and quick changeover3 lessons45m
- 12TPM: what it is and how it grew3 lessons50m
- 13The eight pillars of TPM4 lessons48m
- 14Rolling out TPM and keeping the gains4 lessons57m
- 15Final assessment0 lessons0m
Requirements
- 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.
- 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.
Lean Manufacturing, OEE and TPM at a glance
Lean Manufacturing, OEE and TPM is a free, self-paced online manufacturing excellence course from EDWartens India with 15 modules, 10h 47m of video lessons, written notes, practice tasks and assessments, and an optional verifiable certificate.
- Price
- ₹0, free for good. No trial, no card. Comparable classroom training of this length costs about ₹5,999.
- Format
- 15 self-paced modules, 10h 47m of video, written notes, a quiz per module and a 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, 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
A shareable EDWartens certificate
Finish every module and pass the final assessment, and the optional EDWartens certificate is yours. It carries a unique verification code on a public page anyone can check, so it stands up when a recruiter looks it up. See it below.
- Add it to your LinkedIn profile in one click
- Link it from a CV or portfolio, the URL is permanent
- Publicly verifiable by code, not a PDF anyone can edit
- Issued by EDWartens India, the training centre itself
The course itself stays free whether or not you ever buy one.
Stuck? Ask a practising engineer
A free course usually means a comment section and hope. This one does not. Every module has an Ask-your-trainer panel that reaches the same engineers who teach our paid programme: people who commission panels for a living, not moderators.
- Questions answered in the context of the module you are on
- The same engineers who teach the AEP programme
- Career tools, CV help and public job listings included
- Your progress and notes stay in your account for good
Pairs well with
PLC programming · FreeSiemens TIA PortalFrom zero electrical knowledge to a working, simulated S7-1200 program, for nothing.
PLC programming · FreeSiemens S7-1200 with TIA Portal: The Tutorial SeriesEvery S7-1200 instruction, one short video at a time: bits, edges, timers, counters, comparators, maths, MOVE, conversion, analog scaling, jumps and shift registers.
HMI · FreeSiemens TIA Portal HMI: KTP and Comfort Panels with WinCCEvery screen a plant operator touches, built in TIA Portal: tags, buttons, symbols, numeric input, bar graphs, navigation and templates, trends, alarms, recipes, faceplates, pop-ups, users and languages.
Process control · FreeSiemens TIA Portal PID Compact and Analog ProcessingClosed-loop control the way it is done on an S7-1200 or S7-1500: analog in, NORM_X and SCALE_X, PID_Compact configured, tuned and wired to an HMI, analog or PWM out, proved on a free tank simulation.Learner reviews
No reviews yet
Reviews here are written only by learners who have finished every module of Lean Manufacturing, OEE and TPM, and they are published exactly as written. Finish the course and yours will be the first.
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 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 70 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.
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.
Verifiable by anyone
A unique certificate number and a public verification page. A recruiter checks it in ten seconds.
Adds to LinkedIn in one click
Issuer, credential ID and URL prefilled, with 5 matching skills to pin to your profile.
QR code on the certificate
Scans straight to the verification page, so a printed copy proves itself.
Names what you can do
Lists the topics covered, from lean principles, the eight wastes, gemba walks and bottleneck analysis to the six big losses, smed changeover, and tpm through its eight pillars and twelve steps.
A permanent link
Put it on a CV, a portfolio or an application. The URL never changes.
Earned, not attended
Issued only after every module and a final assessment at 70%, with three attempts. That is why it stands up.
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, ₹459, GST included, with a receipt.
Issued by EDWartens India (Wartens Automation Private Limited) as a Certificate of Completion for this self-paced course. 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.
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.