Mastering Business Excellence · Supply Chain

Mastering Lean Supply Chain

Mastering Lean Supply Chain gives operations teams the Lean and Six Sigma tools to strip waste out of planning, warehousing and logistics flows for good.

Register Now opens this course on the Blue Ocean Academy website in a new tab.

Mastering Lean Supply Chain course
  • Course codeLSSSC
  • LevelProfessional
  • Learning time33 hours
  • Modules21 modules
  • FormatSelf-paced online
  • CredentialMBE credential

About this course

Why it matters

Waste in a supply chain rarely announces itself. It hides in waiting trucks, double handling, overstocked buffers, re-keyed data and the rework that follows a quality miss.

Mastering Lean Supply Chain trains operations staff to see those losses as a system, using the eight wastes, value stream mapping and the process view of work, and then to attack them with 5S, visual management, standard work, kaizen and, where variation is the problem, the Six Sigma DMAIC method. The aim is a workforce that improves flow continuously rather than firefighting.

How it runs for your organization

For an organization the program is 33 hours of self-paced online learning on the Blue Ocean learning platform, licensed for a cohort and tracked on the administrator dashboard.

Participants draw a current-state map of a flow they own, calculate takt time, lead time and value-added ratio, and design a future state, so the first improvement project is already scoped by the time they finish. Successful participants earn a digital, verifiable MBE credential at the end.

What you will learn

  • Compare Lean, Six Sigma and Lean Six Sigma and pick the right approach for a problem
  • Trace the Toyota Production System's two pillars into end-to-end supply networks
  • Describe a supply chain as material, information and cash flows seen through processes
  • Define value from the customer's view and establish flow and pull across a value stream
  • Diagnose muda, mura and muri and the eight wastes in warehousing, logistics and planning
  • Deploy 5S, kanban, andon and standard work to stabilize a supply chain process
  • Draw current-state and future-state value stream maps with takt time and lead time calculated
  • Lead a DMAIC project from charter through root cause analysis to control plans and handover

Skills you will build

  • Lean waste diagnosis
  • Value stream mapping
  • Flow and pull design
  • 5S and visual management
  • Standard work design
  • Kaizen facilitation
  • Process capability basics
  • DMAIC project scoping

Who this course is for

Operations professionals who own a flow, whether a dock, a planning cycle or a delivery route, are the core participants. Warehouse and distribution managers use the tools on picking, putaway and dock congestion. Logistics coordinators apply them to carrier handoffs and the information flow around a shipment.

Supply chain planners and inventory planners learn how pull principles reduce the stock a plan requires. Procurement staff who sit upstream of all of this gain the shared language they need to work with suppliers on waste. Licensing it for a site rather than a function pays off, because most waste lives in the handoffs between departments.

Course outline

The curriculum runs through 21 modules. Modules one to three cover why Lean and Six Sigma matter, Lean's origins and the process view. Modules four and five apply Lean principles and the eight wastes. Modules six to eight supply the toolset: core tools, value stream mapping and kaizen culture.

Module nine introduces the Six Sigma mindset, module ten the DMAIC framework, and modules eleven to fifteen work through define, measure, analyze, improve and control. Modules sixteen to twenty add statistical process control, lean inventory, alignment with SCOR and sustainability, digital Lean and cross-industry cases, and module twenty-one covers leading projects.

21 modules · 84 topics

Module 1Introduction to Lean Six Sigma in Supply Chain Management
  • Why Lean and Six Sigma Matter to Modern Supply Chains
  • Lean, Six Sigma, and Lean Six Sigma Compared
  • Focus, Tools, and the Results Each Approach Seeks
  • Where Each Method Shines: Planning, Procurement, Warehousing, and Logistics
Module 2The Origins and Evolution of Lean: From the Toyota Production System to the Global Supply Chain
  • Craft, Mass, and Lean Production: A Historical Arc
  • The Toyota Production System and Its Two Pillars
  • From the Factory Floor to End-to-End Supply Networks
  • The Convergence of Lean and Six Sigma
Module 3Supply Chain Fundamentals and the Process View
  • The Supply Chain as an Integrated System
  • Core Flows: Material, Information, and Cash
  • Adopting the Process View of Work
  • Suppliers, Customers, and the Value Chain
Module 4Lean Principles Applied to Supply Chains
  • Defining Value from the Customer’s Perspective
  • Mapping the Value Stream End to End
  • Creating Flow and Establishing Pull
  • The Pursuit of Perfection and Continuous Improvement
Module 5Identifying and Eliminating the Eight Wastes in Logistics and Operations
  • The Concept of Muda, Mura, and Muri
  • The Eight Wastes Defined
  • Waste in Logistics, Warehousing, and Planning
  • Diagnosing Waste at the Gemba
Module 6Core Lean Tools for Supply Chain Improvement
  • Building a Stable Foundation for Improvement
  • 5S and Workplace Organization
  • Visual Management: Kanban, Dashboards, and Andon
  • Standard Work and Process Discipline
Module 7Value Stream Mapping and Flow Design for End-to-End Supply Chains
  • Purpose and Power of Value Stream Mapping
  • Drawing the Current-State Map
  • Calculating Takt Time, Lead Time, and Value-Added Ratio
  • Designing the Future-State Map
Module 8Building a Culture of Continuous Improvement: Kaizen, Gemba, and Standard Work
  • The Kaizen Mindset and the PDCA Cycle
  • Going to the Gemba: Leadership at the Real Place
  • Kaizen Events and Daily Improvement
  • Respect for People and Frontline Engagement
Module 9Six Sigma Mindset and Basic Concepts for Supply Chain Management
  • Variation, Defects, and the Cost of Poor Quality
  • Understanding Sigma Levels and Process Capability
  • The Voice of the Customer and Critical-to-Quality Requirements
  • Roles, Belts, and Project Governance
Module 10DMAIC Framework Overview for Supply Chain Projects
  • The Logic of Define-Measure-Analyze-Improve-Control
  • Selecting and Scoping the Right Projects
  • Tollgates and Phase Deliverables
  • DMAIC Versus DMADV and Kaizen
Module 11Define Phase in a Supply Chain Context
  • Clarifying the Business Problem and Goal Statement
  • Building the Business Case and Project Charter
  • Scoping the Project and Identifying Stakeholders
  • SIPOC and High-Level Process Definition
Module 12Measure Phase: Mapping and Quantifying Supply Chain Performance
  • Developing a Data Collection Plan
  • Detailed Process Mapping and Metric Selection
  • Measurement System Analysis and Data Integrity
  • Establishing Baseline Performance
Module 13Analyze Phase: Root Cause Analysis in Logistics and Planning
  • From Symptoms to Root Causes
  • The Five Whys and Fishbone Diagrams
  • Pareto Analysis and Data Stratification
  • Hypothesis Testing and Correlation
Module 14Improve Phase: Designing Practical Supply Chain Solutions
  • Generating and Screening Solution Ideas
  • Error-Proofing and Poka-Yoke in Operations
  • Piloting and Design of Experiments
  • Cost-Benefit and Risk Assessment of Solutions
Module 15Control Phase: Sustaining Supply Chain Gains
  • Standardizing the Improved Process
  • Control Plans and Response Protocols
  • Visual Controls and Ongoing Monitoring
  • Handover to Process Owners
Module 16Statistical Process Control and Data-Driven Decision Making
  • Common-Cause Versus Special-Cause Variation
  • Reading and Building Control Charts
  • Process Capability Indices in Practice
  • Dashboards and Real-Time Performance Signals
Module 17Lean Inventory, Flow, and Demand Variability
  • The True Cost and Function of Inventory
  • Just-in-Time and Pull-Based Replenishment
  • The Bullwhip Effect and Demand Amplification
  • Buffering Strategies: Inventory, Capacity, and Time
Module 18Lean Six Sigma, SCOR, Sustainability, and Resilience
  • Aligning Lean Six Sigma with the SCOR Model
  • Green and Sustainable Lean Practices
  • Building Resilience into Lean Supply Chains
  • Risk, Disruption, and the Efficiency Trade-off
Module 19Digital Lean: AI, Automation, and Industry 4.0 in the Supply Chain
  • The Digital Transformation of Lean Operations
  • IoT, Sensors, and the Digital Gemba
  • Analytics, AI, and Predictive Quality
  • Automation, Robotics, and Digital Twins
Module 20Lean in Practice: Cross-Industry Case Studies
  • Automotive and Discrete Manufacturing
  • Retail and E-Commerce Fulfillment
  • Healthcare and Pharmaceutical Supply Chains
  • Services and Public-Sector Operations
Module 21Designing and Leading Lean Six Sigma Supply Chain Projects
  • Selecting High-Impact Projects Aligned to Strategy
  • Chartering, Resourcing, and Governance
  • Leading Teams and Managing Change
  • Measuring Results and Financial Validation

Frequently asked questions

Is this a Lean program or a Six Sigma program?

Both, in sequence. Modules one to eight are Lean: principles, wastes, tools, value stream mapping and kaizen culture applied to supply chains. Modules nine to sixteen build the Six Sigma side, from variation, sigma levels and the voice of the customer through each DMAIC phase to statistical process control. The later modules bring the two together in lean inventory, digital Lean and project leadership.

What does value stream mapping look like for a supply chain?

Module seven takes an end-to-end view rather than a single workstation. Participants draw the current state across suppliers, warehouse and delivery, calculate takt time, lead time and the value-added ratio, then design a future state with fewer handoffs and less waiting. The exercise is meant to be repeated on a real flow after the module, which is why most cohorts pick one before they start.

How are the eight wastes applied to logistics and warehousing?

Module five first explains muda, mura and muri, then defines the eight wastes and walks through where each appears in logistics, warehousing and planning: empty running, waiting at docks, excess motion in picking, overproduction of forecasts and re-keyed data. It finishes with diagnosing waste at the gemba, the actual place of work, rather than from reports.

Will participants learn how to run a kaizen event?

Module eight covers the kaizen mindset and the PDCA cycle, going to the gemba as a leadership practice, the structure of kaizen events alongside daily improvement, and the respect for people that keeps frontline staff engaged. Combined with the standard work and visual management tools from module six, participants have what they need to lead a first event with their own team.

Does the program suit supply chain planners as well as operations staff?

Yes. The process view in module three and the pull principles in module four apply directly to planning, and the wastes module treats overproduction of plans and excess inventory as waste in their own right. Planners who complete it understand why operations ask for smaller batches and leveled schedules. Module seventeen, on lean inventory, pull replenishment and the bullwhip effect, is written for them.

How long is the program and how is completion tracked?

The content amounts to 33 hours of self-paced online learning on the Blue Ocean learning platform, available on web and mobile, made up of modules, digital study resources, knowledge checks and practice assessments. Managers can see enrollment, progress and completion for every participant on the administrator dashboard. Those who complete successfully receive a digital, verifiable MBE credential.

How do individual learners register for this course?

Use the Register Now button on this page. It opens Mastering Lean Supply Chain on the Blue Ocean Academy website, where individual learners can enroll directly.

How does a corporate license for this course work?

Your organization licenses seats for a cohort or a whole team. Participants study the self-paced modules on the Blue Ocean learning platform, on web or mobile, and your administrator follows enrollment, progress and completion on a dashboard.

Can we start with a pilot cohort before a wider rollout?

Yes. A pilot cohort in one department is a practical first step. Use the corporate license form, and a program advisor will map the relevant courses and license options to your teams.

Ready to get started?

Ask about a corporate license to build Lean capability across planning, warehousing and logistics, or begin with a pilot cohort at one site.

Register Now opens this course on the Blue Ocean Academy website in a new tab.

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