Learning paths

Not sure where to start? Pick a topic and follow the order. Each path goes from beginner to advanced, with free articles, visual maps and official sources. Bookmark this page: it is your way back to keep studying.

Lean Manufacturing 28 articles

From the concept of waste to daily management at the gemba. Start with the principles, master the flow tools, then move on to Lean leadership.

Beginner

  1. Lean Manufacturing: Definition, Principles and Examples
  2. 8 Wastes of Lean (DOWNTIME): Examples and How to Remove Them
  3. Muda, Mura, Muri: The 3 Ms of Lean Explained With Examples
  4. 5S Methodology: Step-by-Step Guide to Implementation
  5. Kaizen: Meaning, Examples and How to Implement It
  6. Toyota Production System: The 14 Principles Explained

Intermediate

  1. Value Stream Mapping (VSM): How to Map, Steps and Example
  2. Takt Time: How to Calculate It, Formula and Worked Example
  3. Kanban System: How Pull Production Works, with Example
  4. Just-in-Time (JIT) Manufacturing: Definition and Example
  5. Heijunka: Production Leveling, Example and How to Do It
  6. Jidoka: Meaning, 4 Steps and Examples of Autonomation
  7. Standardized Work (Standard Work): How to Build It, Example
  8. SMED: Quick Changeover Steps, Examples and Benefits
  9. Poka-Yoke: Error-Proofing Examples, Types and How to Apply
  10. Gemba Walk: How to Do It, Steps, Questions and an Example
  11. Continuous Flow and Bottlenecks: How to Remove Constraints
  12. PDCA Cycle: What It Is, the 4 Steps and a Worked Example

Advanced

  1. Future State Value Stream Map: How to Design It, Step by Step
  2. Hoshin Kanri: Strategy Deployment, Catchball and Example
  3. Toyota Kata: Improvement Kata and Coaching Kata in Practice
  4. Lean Daily Management: Tier Meetings and Escalation
  5. Obeya Room: the Visual Management Room and How to Build One
  6. Lean Leadership: Leader Standard Work and Management at the Gemba
  7. Lean Accounting: Value Stream Costing With a Worked Example
  8. One piece flow: how to implement it and when to use it
  9. Kaizen Event (Kaizen Blitz): How to Plan and Run One in 5 Days
  10. TWI Job Instruction: JI, JM and JR steps with an example

Quality and statistics 30 articles

The basic quality tools, statistical process control and automotive-industry requirements, in order of difficulty.

Beginner

  1. The 7 basic quality tools: what they are and how to use them
  2. Pareto chart: what it is, the 80/20 rule and how to make one
  3. Fishbone diagram (Ishikawa): how to build one with the 6Ms
  4. Check Sheet: How to Build and Use It for Data Collection
  5. Histogram: How to Make and Read One, With Example
  6. 5 Whys: How to Do Root Cause Analysis, With Examples
  7. ISO 9001 Implementation and Certification: A Step-by-Step Guide

Intermediate

  1. Statistical process control (SPC): how to use control charts
  2. Cp and Cpk: how to calculate process capability
  3. X-bar and R Chart: How to Build and Read One, With Example
  4. P-chart: attribute control chart with a worked example
  5. FMEA: what it is, how to do it and how to calculate RPN
  6. 8D Report: The 8 Disciplines Explained with Example
  7. Gauge R&R and MSA: how to evaluate a measurement system
  8. Control Plan: How to Build One, with Example and FMEA Link
  9. ISO 9001 Internal Audit Checklist: Steps and Worked Example
  10. Nonconformity and Corrective Action (CAPA): Handle and Close
  11. Calibration and Measurement Uncertainty: Controlling Instruments
  12. Six Sigma DMAIC: Definition, Phases and Sigma Level Formula

Advanced

  1. Pp and Ppk: Process Performance and How They Differ from Cp, Cpk
  2. CUSUM and EWMA Control Charts: Detect Small Process Shifts
  3. Design of Experiments (DOE): 2² Factorial With Example
  4. Hypothesis Testing and ANOVA for Process Improvement
  5. Western Electric and Nelson Rules for Control Charts
  6. APQP and PPAP: What They Are and How to Apply Them
  7. IATF 16949 Requirements and How to Prepare for Certification
  8. VDA 6.3 process audit: how it works and how to score it
  9. QFD House of Quality: From Customer Voice to Requirements
  10. Attribute Agreement Analysis and Kappa: Worked Example
  11. Lean Six Sigma Green Belt Certification: Belts Explained

Production planning and control 23 articles

From demand forecasting to fine scheduling: how to plan what to produce, when and with which resources.

Beginner

  1. Production planning and control: MPS, MRP and scheduling explained
  2. Production capacity: utilization and efficiency explained
  3. Demand forecasting: moving average and exponential smoothing
  4. Bill of Materials (BOM): Structure, Levels and How to Build One
  5. Manufacturing Routing: Operations, Times and Work Centers
  6. Production Order: What It Is, How to Issue and Report It

Intermediate

  1. MRP: how to calculate material requirements, with an example
  2. Master Production Schedule (MPS): How to Build One
  3. S&OP: sales and operations planning, step by step
  4. Job sequencing rules: FIFO, SPT and EDD compared
  5. Forecast Error: MAPE, MAD and Bias with Example
  6. MRP Lot Sizing: Lot for Lot, POQ and EOQ With Example
  7. Assembly line balancing: how to calculate it with takt time
  8. How Many Operators a Line Needs: Staffing from Takt Time

Advanced

  1. Aggregate Production Planning: Strategies with Example
  2. Holt-Winters Seasonal Forecast: Worked Example
  3. Capacity Requirements Planning (RCCP and CRP): Load Calculation
  4. Finite Capacity Scheduling and APS vs Infinite Loading
  5. Johnson's Rule: Two-Machine Flow Shop Sequencing with Example
  6. Critical Ratio Scheduling Rule and Minimum Slack
  7. Planning Time Fence: Frozen Zone, DTF, PTF and Example
  8. Service Level and Fill Rate: How to Measure and Set Targets
  9. Transfer Batch vs Process Batch: Cut Lead Time

Logistics and inventory 28 articles

Inventory, warehousing, transport and the supply chain, from basic concepts to network and total-cost decisions.

Beginner

  1. Supply Chain Management Explained: Flows, SCOR and Metrics
  2. Inventory management: reorder point, safety stock and EOQ
  3. ABC inventory analysis: how to classify your stock items
  4. Lead time: what it is, how to calculate it and how to cut it
  5. Inventory turnover ratio: formula, days of supply, how to improve
  6. FIFO, LIFO and Weighted Average Inventory Valuation Example

Intermediate

  1. Safety Stock Formula: How to Calculate It, With Example
  2. Economic Production Quantity (EPQ): Formula and Example
  3. Warehouse Management System (WMS): Functions and When to Buy
  4. Order Picking Methods in the Warehouse: Types and Slotting
  5. Cycle Counting Inventory: Count Without Stopping Ops
  6. Cross-Docking: What It Is, Types, Benefits and Cost Example
  7. Milk Run Lean Supermarket: Line Supply and Container Sizing
  8. FEFO vs FIFO in the Warehouse: Which to Use, with Example
  9. Purchasing Management: Process, KPIs and Purchasing Cycle
  10. Supplier Evaluation Scorecard: Criteria, Weights and Rating

Advanced

  1. Bullwhip Effect: Causes, Example and How to Reduce It
  2. XYZ Analysis and ABC-XYZ Matrix for Inventory, with Example
  3. Vendor managed inventory and consignment stock: how they work
  4. Transportation Management System (TMS): Functions and When to Buy
  5. Freight Cost and Total Logistics Cost: How to Calculate
  6. Incoterms 2020 Explained: The 11 Terms and How to Choose
  7. Reverse Logistics: Process, Flows and Manufacturing Examples
  8. Warehouse Sizing: How to Calculate Pallet Positions and Area
  9. AGV and AMR: Autonomous Vehicles for Internal Logistics
  10. Palletizing: Pallet Load Patterns and Utilization Calculation
  11. Pallet Racking: Selective, Drive-In and Push-Back Compared
  12. Returnable Packaging Cost: Fleet Size, Cost per Trip, Payback

Maintenance and reliability 21 articles

From maintenance types and TPM to reliability, vibration diagnosis and asset management.

Beginner

  1. Preventive vs Predictive vs Corrective Maintenance: Differences
  2. TPM: Total Productive Maintenance, 6 Big Losses and Pillars
  3. Autonomous Maintenance: The 7 Steps of the TPM Pillar
  4. MTBF and MTTR: how to calculate key maintenance metrics
  5. Maintenance Plan: From Asset Inventory to Schedule
  6. CMMS maintenance management software: functions and selection

Intermediate

  1. Reliability Centered Maintenance (RCM): the 7 Questions
  2. Bathtub Curve Reliability: Failure Rate and Weibull Explained
  3. Maintenance Shutdown Planning: Scope, Schedule, Critical Path
  4. Spare Parts and MRO Inventory: Criticality and Stock Levels
  5. Industrial Lubrication and Oil Analysis: Plan and Diagnosis
  6. RCFA: root cause failure analysis for equipment, step by step
  7. Maintenance workforce sizing: how many technicians you need
  8. OEE: How to Calculate Overall Equipment Effectiveness
  9. TEEP vs OEE: Differences, Formula and Worked Example

Advanced

  1. Fault Tree Analysis (FTA): AND/OR Gates and Worked Example
  2. Vibration Analysis in Predictive Maintenance, With Example
  3. Infrared Thermography in Predictive Maintenance: How to Apply It
  4. System Reliability: Series and Parallel Formulas and Example
  5. AI predictive maintenance: how it works, data and example
  6. ISO 55000 Asset Management: Principles and How to Start

Industrial costs and finance 23 articles

Unit cost, break-even and pricing, up to evaluating investments in machines and projects.

Beginner

  1. Break-even point: how to calculate it, with example and chart
  2. Manufacturing Cost Calculation: Unit Cost With Example
  3. Contribution margin: formula, example and product mix
  4. NPV, IRR and payback: how to evaluate an investment
  5. Markup vs Margin: How to Set a Manufacturing Selling Price
  6. Machine Hour Rate: How to Calculate It, With a Worked Example

Intermediate

  1. Absorption Costing: How to Allocate Overhead and When to Use It
  2. Activity-Based Costing (ABC): Steps and Worked Example
  3. Standard Costing and Variance Analysis: Worked Example
  4. Make or buy decision: how to decide with numbers
  5. Machine Depreciation Methods: Worked Example and Formulas
  6. Production Budget: How to Build a Manufacturing Budget
  7. Rework vs Scrap: How to Decide by Cost, with an Example
  8. Cash Conversion Cycle and Working Capital in Manufacturing
  9. Cost of quality: the PAF model with an example

Advanced

  1. TCO: total cost of ownership when buying machinery
  2. Capital Budgeting and CAPEX in Industrial Projects
  3. ROI and EVA in manufacturing: worked example
  4. Sensitivity Analysis for Investment: NPV, Scenarios, Example
  5. Degree of Operating Leverage (DOL): Formula and Example
  6. Multi-product break-even: sales mix and average margin
  7. Throughput Accounting: How to Decide by the Bottleneck
  8. Value Engineering and Value Analysis: Function, Cost, Value

Industry 4.0 and automation 20 articles

How to start digitalizing the factory without losing the Lean focus: systems, sensors, data and security.

Beginner

  1. Industry 4.0 in manufacturing: technologies and how to start
  2. 7 Characteristics of Industry 4.0 You Need to Know
  3. Industry 4.0 vs Lean Manufacturing: Differences and Synergy
  4. Digital Transformation: 5 Steps to Adopt Industry 4.0
  5. Manufacturing ERP: Modules, How It Works and How to Choose
  6. RFID vs Barcode in Manufacturing: Tracking and How to Choose

Intermediate

  1. Manufacturing Execution System (MES): Functions and ERP Link
  2. Industrial IoT (IIoT) architecture: layers, use cases, payback
  3. PLC and Industrial Automation: Pyramid, Ladder and SCADA
  4. Production Dashboard KPIs: Layout, Traffic Lights, Example
  5. Collaborative Robots (Cobots): Uses, Safety and Payback
  6. Paperless Factory: Digitize Work Orders and Shop Floor Records
  7. Big Data Manufacturing Analytics: From Data to Decision

Advanced

  1. Digital twin in manufacturing: what it is and when it pays off
  2. Machine vision quality inspection: uses and limits
  3. OPC UA and Edge Computing: Connecting Machines to Systems
  4. Industrial Cybersecurity (OT Security): Risks and Segmentation
  5. Additive Manufacturing: Industrial 3D Printing, Uses and Costs
  6. Augmented Reality in Industry: Maintenance and Training
  7. Industry 5.0 vs Industry 4.0: Differences and Factory Impact

Management, projects and operations research 22 articles

Management and project tools, and the mathematical models that support production decisions.

Beginner

  1. 5W2H action plan: how to build one, with an example
  2. GUT Matrix Prioritization: Scoring, Example and Template
  3. Gantt Chart: How to Create One Step by Step, With Example
  4. Work Breakdown Structure (WBS): How to Build One, With Example
  5. SWOT Analysis in Manufacturing: Template, Example and TOWS
  6. RACI Matrix: Roles in Projects and Processes, with Template

Intermediate

  1. Critical path method (CPM) and PERT: a worked example
  2. Balanced Scorecard in Manufacturing: 4 Perspectives, Example
  3. Change Management: ADKAR and Kotter's 8 Steps on the Shop Floor
  4. Stakeholder Analysis: Power Interest Grid with Example
  5. Project Risk Register: Template, Scale and Worked Example
  6. Weighted Decision Matrix and Pugh Matrix: How to Use Them
  7. Linear programming and the simplex method: a worked example
  8. Benchmarking: Types, Steps and a Performance Gap Example
  9. Lessons Learned Knowledge Management: Capture and Apply

Advanced

  1. Earned Value Management and S-Curve: Control Cost and Schedule
  2. Agile Scrum in Manufacturing Improvement Projects
  3. Queuing theory: the M/M/1 model with a worked example
  4. Monte Carlo Simulation in Planning: Simple Worked Example
  5. Decision Tree Expected Monetary Value: Method and Example
  6. Vehicle Routing and Traveling Salesman: Nearest Neighbor, 2-opt
  7. Six Sigma Project Charter: Template, Fields and Worked Example

Safety, ergonomics and methods 21 articles

From time study and ergonomics to safety standards, risk management and the environment.

Beginner

  1. Ergonomics in assembly lines: less effort, less lost time
  2. Time study: how to calculate standard time with an example
  3. Learning curve: formula, example and how to use it
  4. Risk Matrix and Preliminary Hazard Analysis: Worked Example
  5. Toolbox Talk Safety: How to Run and Document Daily Talks
  6. Accident Frequency Rate: TRIR and LTIR Formulas, Example

Intermediate

  1. Machine safety standards and lean: guarding without downtime
  2. Occupational risk management program: risk register and plan
  3. ISO 45001 Occupational Health and Safety: Requirements Guide
  4. Lockout Tagout Procedure: 8 Steps With a Press Example
  5. Accident Investigation: Root Cause Tree Method, With Example
  6. Permit to Work (PTW): Process, Template and Examples
  7. RULA REBA ergonomic assessment: scoring and action levels
  8. Work Sampling: Formula, Sample Size and Worked Example
  9. Industrial Engineering: What It Is, Key Areas and Career Paths

Advanced

  1. HAZOP study guide words: steps, worksheet and worked example
  2. Behavior Based Safety (BBS): How to Apply It, With Example
  3. MTM Predetermined Time Systems: Estimate Time Without a Stopwatch
  4. ISO 14001 Environmental Management: Requirements and Steps
  5. Industrial Energy Efficiency: Audit and Practical Actions
  6. Industrial Waste Management: Plan, Classes and Disposal

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