Production Course

Lesson 1 • Introduction to Production Metrics

Presents the fundamental KPIs used to measure production health and operational performance. Metrics literacy is prerequisite to every analytical chapter that follows.

Lesson 2 • What Production Management Means

Defines production management scope, distinguishing it from project management and operations. Anchors the chapter by establishing the conceptual frame for all subsequent topics.

Lesson 3 • Core Production Terminology

Introduces standardised vocabulary used across production disciplines. Consistent terminology prevents miscommunication and accelerates onboarding into any production team.

Lesson 4 • Production Workflow Basics

Outlines how work moves through a production system from input to output. Provides the structural mental model needed before studying optimisation techniques.

Lesson 1 • Capacity Planning Techniques

Addresses finite and infinite capacity planning methods and their trade-offs. Capacity alignment prevents schedule failures before they reach the shop floor.

Lesson 2 • Schedule Execution and Adjustment

Covers daily schedule release, monitoring, and real-time replanning when disruptions occur. Closes the planning loop by connecting plans to actual production outcomes.

Lesson 3 • Demand Forecasting for Production

Covers quantitative and qualitative forecasting methods that feed production planning. Accurate demand signals are the starting point for every scheduling decision.

Lesson 4 • Material Requirements Planning

Explains how MRP translates the MPS into component and raw material orders. Students connect scheduling decisions to procurement and inventory outcomes.

Lesson 1 • Capacity Expansion Decision Making

Provides a framework for evaluating when and how to add permanent capacity. Links operational data to capital investment justification.

Lesson 2 • Equipment and Asset Utilisation

Teaches how to measure, analyse, and improve equipment utilisation rates. High asset utilisation is a primary lever for cost reduction and output growth.

Lesson 3 • Constraint Management

Applies the Theory of Constraints to identify and exploit system bottlenecks. Constraint focus maximises throughput without proportional cost increases.

Lesson 4 • Workforce Planning in Production

Covers headcount modelling, shift design, and skill-mix analysis for production environments. Workforce decisions directly determine achievable throughput and schedule reliability.

Lesson 1 • Quality Management Principles

Establishes the philosophical and systemic foundations of quality in production. Shared quality principles align all team members toward defect prevention rather than detection.

Lesson 2 • Inspection and Sampling Methods

Covers acceptance sampling plans and in-process inspection strategies. Sampling design balances detection confidence against inspection cost and throughput impact.

Lesson 3 • Statistical Process Control

Teaches control chart construction and interpretation for monitoring process stability. SPC enables operators to distinguish normal variation from assignable causes.

Lesson 4 • Root Cause Analysis Techniques

Introduces structured methods for identifying and eliminating defect root causes. Systematic root cause analysis prevents recurrence and reduces chronic quality losses.

Lesson 1 • Lean Principles and Value Thinking

Introduces the five lean principles and the concept of value from the customer's perspective. Lean thinking reframes every production decision around value delivery.

Lesson 2 • Value Stream Mapping

Teaches current-state and future-state value stream mapping as a diagnostic and design tool. VSM reveals systemic muda invisible at the individual process level.

Lesson 3 • 5S Workplace Organisation

Covers the Sort, Set, Shine, Standardise, Sustain methodology for workplace organisation. 5S creates the visual order that makes abnormalities immediately apparent.

Lesson 4 • Kaizen and Continuous Improvement

Structures rapid improvement events and daily kaizen habits for sustained lean progress. Continuous improvement culture prevents backsliding after initial lean gains.

Lesson 1 • Cost Reduction Strategies

Presents structured approaches to reducing production costs without sacrificing quality or delivery. Cost reduction is framed as a systematic process, not arbitrary cutting.

Lesson 2 • Production Cost Structure

Breaks down direct materials, direct labour, and overhead into their production cost components. Understanding cost structure is prerequisite to any cost reduction or pricing analysis.

Lesson 3 • Production Budgeting and Forecasting

Covers construction of production budgets and rolling cost forecasts aligned to the production plan. Budget discipline connects operational decisions to financial accountability.

Lesson 4 • Activity-Based Costing in Production

Applies activity-based costing to assign overhead more accurately to products and processes. ABC exposes hidden cost drivers that standard costing systems obscure.

Lesson 1 • Inbound Logistics and Receiving

Explains inbound freight management, receiving inspection, and material flow into production. Reliable inbound logistics prevents material shortages that halt production.

Lesson 2 • Outbound Logistics and Order Fulfilment

Covers finished goods handling, order picking, and outbound shipment to customers. Outbound performance is the final measure of production system effectiveness.

Lesson 3 • Supplier Selection and Development

Covers criteria and processes for qualifying, selecting, and developing production suppliers. Supplier quality and reliability directly determine production input stability.

Lesson 4 • Production-Driven Procurement

Aligns purchasing decisions with production schedules and inventory policies. Procurement timing and quantity decisions directly affect production cost and continuity.

Lesson 1 • Production System Design Principles

Applies systems thinking to design or redesign production layouts, flows, and control logic. System design decisions lock in performance potential for years of operation.

Lesson 2 • Digital Tools and Production Analytics

Introduces digital manufacturing tools, real-time data collection, and advanced analytics for production. Data-driven operations enable faster, more accurate management decisions.

Lesson 3 • Operational Excellence Programmes

Structures enterprise-wide operational excellence initiatives that sustain and compound improvements. OpEx programmes institutionalise improvement as a core business capability.

Lesson 4 • Sales and Operations Planning

Teaches the S&OP process that aligns production, supply chain, and commercial plans monthly. S&OP is the governance mechanism that keeps all functions synchronised.