Mahindra Lean Bronze Certification

The programme aims to develop basic lean management competencies and application
Program Overview orientation amongst participants enabling them to create a Lean culture at their workplace

SYLLABUS
Day Contents

A.Improtance of Lean Manufacturing, Customer Needs, Business Needs

B.Lean History - Craft,Mass and Lean Mfg Characteristics
1 C.Henry Ford, Toyoda's Contribution
D.Lean Principles and identification of wastes
E.Standerdization and Stability

A.Value Stream Maps - Concept and use

2 B.VSM Case study sharing
 Post Graduate Diploma in Operations Management (PGDOM)

This is a unique program that fulfils the growing demand for techno-managerial leaders. Laden with latest management skills & cutting edge technology knowledge, these
professionals will be readied for meeting the challenges offered by the new wave of operational Excellence. This part time residential programme has a built in
Program Overview Operationations Management Focus that helps to appreciate an industry's metamorphosis in competitive times. With an increasing competitive environment, there is a
need to create critical mass of competent and visionary Operational Managers to steer companies towards operational excellence.

The program will be conducted in 3 phases :- Phase 1 : Residential Training

Program Structure - 15 days ( followed by 4 months Project at workplace ) Phase 2 : Residential Training - 15 days (followed by 3 months
project at workplace ) Phase 3 : Residential Training - 15 days (followed by 3 months project at workplace)

Pre Reads are recommended for certain subjects before start of each phase to give basic idea of the subject
SYLLABUS
Sr.No. Module Topic Contents

Introdcution to OM Operation management, Importance of OM in organization, input-output process, challenges in operation management

Planning & Control Production forecasting, Scheduling, Material requirement planning, procurement, sourcing, and ERP
Module 1
1 Operation
Management- Basics
Operations - Basics Work Station Standardization, 5S, Process planning and control

Problem solving and Decision Problem solving methods by decision making methods, and business statistics
making

Top Management Leadership Approach to 'Management of Strategy' and Policy deployment, Balanced score card, linkage to daily operations management
& Strategy
Module 2
2 Long term strategy & Operations strategy Introduction to operation strategy, top-down and bottom up approaches , market requirements and operation resources to operation
deployment strategy

Risk management Identification of risk associated with the operation process, prevention of failure from risk, recovery from failure due to risk

Project Management Project portfolio management, dashboard, KPI's, project management models, project life cycle

Planning and Budgeting Scope of work, Project master plan preparation, monitoring and controlling, CPM, PERT, trade off analysis, project cost estimates, budget
Module3
estimates and its analysis,
3 Project Management
Contract and Claims Legal framework of contract, contract issues, solving disputes, contract payment and change management, claim management and claim
avoidance

Project crisis management Managing project crisis, types of crisis, dealing with crisis

Procurement management Procurement planning and strategy, selection of RFQ, RFP methos, preparation of solicitation documents, sourcing of suppliers, bid receipt,
opening, evaluation, contract management, biling and invoicing

Distribution network Design of distribution network from Supplier to customer, factors affecting distribution network, Applications of distribution network

Module 4 Types of inventory, Economic order quantity, handling and storing equipment and managing economies of scale, inventory management
4 Supply chain Inventoring and warehousing systems
Management

SCM strategies and metrics Identify the major drivers of SCM and their roles (Logistical & cross functional), design of key metrics that track the performace of SCM.

Logistics, Queing and Transportation decisions, Third party logistis, global logistics, queing theory and simulation theory
Simulation

Employee Involvement Managing people at job, design of effective communicaition channels, conflict management and negotitation
Module 5
5 Operational Excellence
through emplooyee Employee Development Managing personal excellence, developing and maintaining industrial relationships with help of case studies and group activities
involvement

Introduction to Lean Introduction to lean operation and pillars of lean operations (JIT, Jidoka, heijunka, TPM, VSM, kaizen)
Operations

6 Module 6 Lean Management VSM, Quick wins through VA/NVA analysis, lean tools
World Class Operations

World Class Operations Business process reengineering, manufacturing ergonomics, Total productive maintenance, Sustainability & Green Manufacturing,
environment health and safety, Energy management

OM Enabler Introduction to cost accounting (direct and indirect costing, material based costing, labour costing, marginal costing, standard costing) and
Financial management, break even analysis and working of capital management

Company visit Application and business orientation through visits to Service operations.

Module 7
7
Business Orientation Guest lectures Guest lectures by business leaders

Project Work Application of learnings at the workplace.

Case study and group activity Small group activities & other practices for employee Involvement, case study.

Advanced supply chain Supply chain innovation, RFID and recent advances in technology, supply chain for E-commerce, customer and supplier relationship
management management
Eelctive 1 Basics of SCM analytics like data collection and aggregation, analysis of data, understanding the analysed data relation to SCM, developing
8a Advanced supply chain Supply chain analytics
management strategies for the results obtained to improve performance

SCM best practices 10 ways to built best preactices in supply chain management

Innovation process through Seperation principle for contradictions, ideality, ideal final result and system resources, S filled model and harmful effect elimination, function
TRIZ and attribute analysis and trimming of components, forty TRIZ principles and case-studies
Eelctive 2
8b Advanced world class System Efficiency
manufacturing Improvement Techniques lean simulation, top down and functional deployment map, Future VSM , MSA, sigma level calculation.

Levelled production & Circular Levelling by volume, levlling by product, demand levelling, introduction to circular manufacturing- a shift from linear to circular
Manufacturing manufaturing/economy

Front desk operations Functions of the Front Office, Customer Service, Dealing with Grievances & Complaints, Understanding Communication, Conversation
Development, Promotions and Customer Relations, Client Interpersonal Skills
Elective 3
8c Hospitality Types of Food Service (eg. Room Service, Bar, Restaurant, Coffee Shop etc), Service Facilities, Food Service Management, Food Purchasing,
Management Food & Bevrage service Dealing with Complaints, Menu planning

Facility management Daily, Periodic and Planned Preventative Maintenance, Frequent Maintenance Problems, Safety, Furniture, Fittings, Managing Maintenance,
Building Maintenance, Toilets and Locker Rooms

Post Programme Application :- Projects on lean operations, SCM metrics, decision tree metrics

Eligibility criteria : Graduate Executives with 5-15 years experience from middle management in non-manufacturing service functions like plant operations, SCM, maintenance, after sales services,
support funcitons, hospitality management etc. are eligible to apply.

Venue : The residential training program will be conducted at : Mahindra Institute of Quality, Govardhan Village, Opp Yashwantrao Chavan Maharashtra Open University (YCMOU), Off Gangapur Road, Nasik
- 422 222, Maharashtra.