Lean Enterprise for the Expert

Course Description

ETI 2623 – Lean Enterprise for the Expert is a sophomore-level, 3-credit-hour course within the Engineering Technologies / Industrial Systems Technology taxonomy of Florida's Statewide Course Numbering System (SCNS). This course provides an advanced study of Lean Enterprise principles, tools, and strategies for experienced practitioners seeking to lead and sustain enterprise-wide continuous improvement initiatives. Building on foundational Lean concepts, students examine the integration of Lean thinking across all organizational functions — including manufacturing, supply chain, new product development, and administrative services — with an emphasis on advanced tool application, cultural transformation, and strategic deployment. The course prepares students to function as Lean change agents, project leaders, and internal coaches within their organizations.

Learning Outcomes

Required Outcomes

Upon successful completion of this course, students will be able to:

• Apply the five core principles of Lean thinking (Value, Value Stream, Flow, Pull, and Perfection) at an advanced, enterprise-wide level.
• Conduct and facilitate advanced Value Stream Mapping (VSM), including current-state analysis, future-state design, and implementation roadmap development.
• Plan, lead, and facilitate Kaizen events (Kaizen Blitz) to achieve rapid, focused process improvements across multiple functional areas.
• Identify, classify, and systematically eliminate the eight wastes (DOWNTIME) across manufacturing, service, and administrative environments.
• Apply DMAIC methodology (Define, Measure, Analyze, Improve, Control) to complex, cross-functional process improvement projects.
• Design and implement Pull systems and Kanban strategies to optimize workflow and reduce work-in-process inventory.
• Develop and deploy Standard Work documentation and visual management systems to sustain process improvements.
• Communicate Lean Six Sigma concepts and results to diverse organizational stakeholders using appropriate data, metrics, and reporting tools.

Optional Outcomes

Depending on course section and instructional emphasis, students may also:

• Apply Design of Experiments (DOE) and Statistical Process Control (SPC) techniques to support data-driven decision making.
• Evaluate and apply Lean principles in service, healthcare, and transactional environments beyond traditional manufacturing.
• Develop a Lean transformation roadmap for a selected business unit or organization using a structured deployment model.
• Mentor and coach Yellow Belt and Green Belt practitioners on the application of Lean tools and project execution.
• Apply the Theory of Constraints (TOC) and bottleneck analysis to optimize enterprise throughput.
• Analyze Lean supply chain strategies including vendor partnerships, demand-driven replenishment, and logistics optimization.

Major Topics

Required Topics

The following content areas are standard across Florida college offerings of this course:

• Advanced Lean Principles Review — Revisiting the Toyota Production System (TPS) origins, the five Lean principles, and the cultural philosophy of continuous improvement (Kaizen).
• Advanced Value Stream Mapping — Current-state and future-state mapping, takt time calculation, lead time analysis, and implementation planning.
• 8 Wastes (DOWNTIME) — In-depth analysis: Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion, and Extra-processing, across multiple industry sectors.
• Kaizen Events and Facilitation — Planning, executing, and sustaining rapid improvement events; team dynamics and change management within a Kaizen structure.
• Pull Systems and Kanban — Single-piece flow, batch reduction, Kanban card systems, supermarket design, and FIFO lanes.
• Standard Work and Visual Management — Work combination sheets, operator balance charts, 5S+Safety implementation, andon systems, and visual workplace design.
• DMAIC Framework at the Advanced Level — Project chartering, VOC analysis, process capability studies, root cause analysis tools (Fishbone, 5 Whys, Pareto), and control plan development.
• Lean Metrics and Key Performance Indicators (KPIs) — OEE (Overall Equipment Effectiveness), cycle time, takt time, first-pass yield, and cost of poor quality (COPQ).
• Change Management and Lean Culture — Leadership roles in Lean transformation, sustaining improvement, resistance management, and building a continuous improvement culture.
• Lean Project Execution — Capstone or team-based applied project applying Lean tools to a real or simulated industrial scenario.

Optional Topics

The following topics may be covered depending on program context and instructor emphasis:

• Statistical Process Control (SPC) — Control charts (X-bar, R-chart, P-chart), process capability indices (Cp, Cpk), and measurement system analysis (MSA/Gage R&R).
• Design of Experiments (DOE) — Full and fractional factorial designs, main effects, interaction plots, and robust design principles.
• Lean in Service and Healthcare Environments — Application of Lean tools to transactional processes, patient flow, administrative workflows, and supply logistics.
• Theory of Constraints (TOC) — Identification and exploitation of system bottlenecks, throughput accounting, and drum-buffer-rope scheduling.
• Lean Supply Chain Management — Supplier development, demand-driven replenishment, vendor-managed inventory (VMI), and total landed cost analysis.
• A3 Problem Solving and Reporting — Structured one-page problem-solving and communication using the A3 format aligned to PDCA (Plan-Do-Check-Act).
• Design for Lean / DFSS Fundamentals — Integrating Lean and Six Sigma principles into new product and process development (DFSS/DFMA concepts).

Resources & Tools

Recommended textbooks, tools, and resources commonly used in Florida college sections of this course:

• Textbooks: Learning to See by Rother & Shook (Lean Enterprise Institute); The Lean Toolbox by Bicheno & Holweg; Lean Thinking by Womack & Jones.
• Software & Simulation Tools: Value stream mapping software (Lucidchart, Microsoft Visio); process simulation tools; Excel-based data analysis templates.
• Professional Organizations: Lean Enterprise Institute (LEI); American Society for Quality (ASQ); Society of Manufacturing Engineers (SME).
• Online Platforms: Florida Shines (for articulation and transfer information); SME's Tooling U-SME for supplemental industrial training modules.
• Lean Simulation Kits: Physical or virtual Lean simulation games (e.g., paper airplane factory, dice games) for experiential learning of flow and pull concepts.

Career Pathways

Completion of ETI 2623 supports workforce readiness and career advancement in the following occupational areas:

• Continuous Improvement Manager / Lean Manager — Leads enterprise improvement initiatives and coaches improvement teams.
• Industrial / Manufacturing Engineer — Designs and optimizes production systems using Lean and industrial engineering methods.
• Quality Engineer / Quality Assurance Manager — Applies DMAIC and Lean tools to reduce defects and ensure product/service quality.
• Operations Manager / Plant Manager — Oversees manufacturing or service operations with a focus on efficiency, cost reduction, and throughput.
• Supply Chain Analyst / Logistics Coordinator — Applies Lean principles to procurement, warehousing, and distribution operations.
• Process Improvement Consultant — Provides internal or external advisory services for organizational Lean transformation.

This course supports transfer pathways into Bachelor of Applied Science (BAS) programs in Industrial Management, Engineering Technology Management, or related fields offered at Florida State College at Jacksonville (FSCJ), University of North Florida (UNF), Florida Polytechnic University, and other Florida institutions.

Special Information

Certification Preparation

Content in ETI 2623 directly aligns with the bodies of knowledge for the following industry-recognized certifications. Students are encouraged to pursue certification as a complement to their academic credential:

• ASQ Certified Lean Six Sigma Green Belt (CLSSGB) — Offered by the American Society for Quality; validates competency in Lean Six Sigma tools and DMAIC project leadership.
• Council for Six Sigma Certification (CSSC) Green Belt or Black Belt — The College of Central Florida is a registered training provider; completion of this course fulfills significant preparation requirements.
• SME Lean Bronze / Silver Certification — Offered by the Society of Manufacturing Engineers; aligns with the Lean Competency Model covered in this course.
• ASQ Lean Essentials I Certification — Entry-level Lean credential appropriate for students early in their Lean practitioner career path.

Program Context

ETI 2623 is typically offered as an advanced course within the Industrial Systems Technology A.S. degree or Lean Six Sigma College Credit Certificate (CCC) at participating Florida colleges. Students completing this course alongside ETI 2610 (or equivalent) and related quality/industrial coursework may be eligible for stackable credentials recognized by Florida's Division of Career and Adult Education (DCAE). Employers in Florida's manufacturing, aerospace, healthcare, and logistics sectors actively recruit graduates with demonstrated Lean practitioner expertise.