Production Engineer Course

Lesson 1 • Production System Mapping

Introduces tools for visualizing material and information flows. Builds the analytical foundation for process improvement work.

Lesson 2 • Manufacturing Systems Overview

Surveys major production system types and their structural logic. Provides context for selecting appropriate engineering approaches.

Lesson 3 • Role of the Production Engineer

Defines the production engineer's scope within manufacturing organizations. Connects daily responsibilities to broader operational and business goals.

Lesson 4 • Safety and Regulatory Fundamentals

Introduces workplace safety principles and regulatory compliance frameworks. Establishes non-negotiable baseline behaviors for all production activities.

Lesson 1 • Process Optimization Techniques

Applies structured methods to improve process performance beyond waste removal. Connects optimization tools to measurable output improvements.

Lesson 2 • Work Measurement and Time Study

Introduces methods for quantifying labor content and setting time standards. Provides data for staffing, scheduling, and efficiency benchmarking.

Lesson 3 • Waste Identification and Elimination

Applies lean thinking to identify and remove non-value-adding activities. Builds the analytical habit of questioning every step in a process.

Lesson 4 • Facility and Workstation Layout

Teaches spatial arrangement of equipment and workstations for flow efficiency. Directly impacts cycle time, ergonomics, and material handling costs.

Lesson 1 • Failure Mode and Effects Analysis

Applies FMEA to proactively identify and mitigate production failure risks. Integrates risk prioritization into process design and control planning.

Lesson 2 • Quality Management Fundamentals

Establishes quality philosophy, cost of quality, and system-level thinking. Frames quality as an engineering discipline, not just inspection.

Lesson 3 • Statistical Process Control

Teaches control chart construction and interpretation for process monitoring. Enables engineers to distinguish common cause from special cause variation.

Lesson 4 • Measurement System Analysis

Evaluates the reliability and accuracy of measurement tools and methods. Ensures data used for decisions is trustworthy and fit for purpose.

Lesson 1 • Material Requirements Planning

Applies MRP logic to calculate material needs from the master schedule. Ensures components arrive on time without excess inventory accumulation.

Lesson 2 • Aggregate Production Planning

Develops medium-term plans balancing workforce, inventory, and capacity. Connects strategic demand signals to operational resource decisions.

Lesson 3 • Master Production Scheduling

Translates aggregate plans into item-level time-phased schedules. Provides the primary input for material and capacity requirements planning.

Lesson 4 • Capacity Planning and Scheduling

Evaluates and adjusts capacity to execute production plans without overload. Resolves conflicts between demand requirements and available resources.

Lesson 1 • Replenishment System Design

Teaches fixed-order and fixed-interval replenishment models and their applications. Enables engineers to select and configure appropriate reorder systems.

Lesson 2 • Supplier Management and Development

Covers supplier selection, qualification, and performance management processes. Strong supplier relationships directly reduce production disruption risk.

Lesson 3 • Supply Chain Risk and Resilience

Identifies supply chain vulnerabilities and mitigation strategies for production continuity. Builds resilience thinking into procurement and logistics decisions.

Lesson 4 • Lean Inventory and Pull Systems

Applies kanban and pull-based replenishment to reduce inventory waste. Connects lean inventory principles to production flow and responsiveness.

Lesson 1 • Predictive Maintenance Technologies

Covers condition-monitoring techniques that detect failure precursors before breakdown. Enables data-driven maintenance timing to maximize equipment uptime.

Lesson 2 • Preventive Maintenance Programs

Designs time-based maintenance schedules to prevent unplanned failures. Balances maintenance cost against the cost of production downtime.

Lesson 3 • Root Cause Analysis for Failures

Applies structured problem-solving to identify and eliminate equipment failure causes. Prevents recurrence by addressing root causes rather than symptoms.

Lesson 4 • Total Productive Maintenance

Applies TPM principles to engage operators in equipment care and improvement. Reduces chronic losses through autonomous and planned maintenance integration.

Lesson 1 • Kaizen Event Facilitation

Teaches the structure and facilitation of focused rapid improvement events. Builds team-based problem-solving capability within production environments.

Lesson 2 • 5S Workplace Organization

Implements the 5S methodology to create organized, visual, and safe workplaces. Provides the stable foundation required for all other lean improvements.

Lesson 3 • Six Sigma DMAIC Methodology

Applies the DMAIC framework to reduce process variation and defect rates. Integrates statistical tools with structured problem-solving for complex issues.

Lesson 4 • Lean Thinking and Value Streams

Establishes lean philosophy and value stream mapping as the primary improvement lens. Connects customer value to every step in the production process.

Lesson 1 • Technology and Automation Strategy

Evaluates automation investments using technical and financial criteria. Guides engineers in selecting and justifying technology upgrades for production.

Lesson 2 • New Product Introduction Process

Manages the engineering activities required to launch new products into production. Reduces launch risk through structured readiness gates and cross-functional coordination.

Lesson 3 • Cost Engineering and Reduction

Applies cost analysis techniques to identify and capture production cost savings. Connects engineering decisions directly to product and operational profitability.

Lesson 4 • Production Transformation Roadmapping

Develops multi-year improvement roadmaps aligned to business strategy. Equips engineers to lead systemic change rather than isolated improvements.