Lean Manufacturing with AI
The Smart Factory Playbook
Cut waste and stabilize flow, the 8-Waste Walk, Kanban pull systems, SMED changeover races and AI-assisted quality and maintenance basics for modern factories.
Who it is for: Production supervisors, plant engineers, CI specialists and operations managers in manufacturing environments.
Created by
ZLearning Faculty
Instructor
ZLearning Faculty
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one-time · ≈ $3.13 per course day
- All 15 days, fully interactive
- Copy-paste prompt vaults in every day
- Auto-saved workbooks + download kits (PDF, Word)
- Knowledge quests with instant feedback
- Official certificate of completion
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Digital product, non-refundable once delivered, unless the course differs from this page. Refund policy
- Duration
- 15 days
- Learn
- 120 min/day
- Total time
- 30 hours
- Price
- $47 one-time
- Level
- All levels · Shop-floor friendly
- Access
- Lifetime + certificate
Start free. Upgrade when you are convinced.
Try the complete first day with any account, then decide. No card, no trial timer, no pressure.
Free Introduction
The complete Day 1 experience, the same lesson paying students get, in your portal.
- Full Day 1, every section, interactive
- Real prompt vault + hands-on mission
- Workbook + knowledge quest with instant feedback
- Progress saved in your own portal
- Signup only, no payment details
Instant portal access after signup
Full Course
Every day of the 15-day journey, plus your official certificate.
- All 15 days, fully interactive
- Copy-paste prompt vaults in every day
- Auto-saved workbooks + download kits (PDF, Word)
- Official certificate of completion
- Lifetime access, one-time payment
Secure Stripe checkout · one-time · lifetime access
What You Will Learn
Concrete, job-ready outcomes, hover (or tap) any point to see exactly where and how it is practiced inside the course.
- Spot and name all 8 wastes with the DOWNTIME Waste Walk
Hands-on practice, Built inside the course
You will practice this in a guided interactive lesson with a copy-paste prompt vault, a hands-on mission on your own real work, an auto-saved workbook and a knowledge quest, the same engine every day of this course runs on.
ChatGPTClaudeGoogle Sheets - Launch a two-card Kanban pull system in one week
Hands-on practice, Built inside the course
You will practice this in a guided interactive lesson with a copy-paste prompt vault, a hands-on mission on your own real work, an auto-saved workbook and a knowledge quest, the same engine every day of this course runs on.
ChatGPTClaudeGoogle Sheets - Run SMED changeover races to reclaim machine hours
Hands-on practice, Built inside the course
You will practice this in a guided interactive lesson with a copy-paste prompt vault, a hands-on mission on your own real work, an auto-saved workbook and a knowledge quest, the same engine every day of this course runs on.
ChatGPTClaudeGoogle Sheets - Build standard work that survives audits and turnover
Hands-on practice, Built inside the course
You will practice this in a guided interactive lesson with a copy-paste prompt vault, a hands-on mission on your own real work, an auto-saved workbook and a knowledge quest, the same engine every day of this course runs on.
ChatGPTClaudeGoogle Sheets - Use AI for quality logs, Pareto analysis and maintenance notes
Hands-on practice, Built inside the course
You will practice this in a guided interactive lesson with a copy-paste prompt vault, a hands-on mission on your own real work, an auto-saved workbook and a knowledge quest, the same engine every day of this course runs on.
ChatGPTClaudeGoogle Sheets - Run daily 5-minute tier meetings that fix problems at the source
Hands-on practice, Built inside the course
You will practice this in a guided interactive lesson with a copy-paste prompt vault, a hands-on mission on your own real work, an auto-saved workbook and a knowledge quest, the same engine every day of this course runs on.
ChatGPTClaudeGoogle Sheets - Map value streams and find the true bottleneck
Hands-on practice, Built inside the course
You will practice this in a guided interactive lesson with a copy-paste prompt vault, a hands-on mission on your own real work, an auto-saved workbook and a knowledge quest, the same engine every day of this course runs on.
ChatGPTClaudeGoogle Sheets - Prepare your plant for smart-factory basics (sensors, data, dashboards)
Hands-on practice, Built inside the course
You will practice this in a guided interactive lesson with a copy-paste prompt vault, a hands-on mission on your own real work, an auto-saved workbook and a knowledge quest, the same engine every day of this course runs on.
ChatGPTClaudeGoogle Sheets
Inside the Course
The engine behind every single day, hover (or tap) any card to see exactly what is included.
15 Days × 120 Min
A complete guided journey, one focused session a day, fully interactive, zero fluff.
Copy-Paste Prompt Vault
A professional prompt vault in every day, copy, paste, get results. Prompts become your assets.
Fully Engaging Workbooks
Interactive in-app workbooks with auto-save, plus fillable PDF, Word and printable versions.
Real-World Missions
Every exercise uses your actual job context, not toy examples. Practice while you learn.
Progress That Shows Everything
A living dashboard tracks every section, quiz and workbook field, and flags what is missing.
Certificate of Completion
Finish the journey and graduate with an official ZLearning certificate for your resume and LinkedIn.
Day-by-Day: Key Highlights
Exactly what happens on each day of your 15-day journey, hover (or tap) any day to see the full detail. Each day blends interactive lessons, a prompt vault, hands-on missions on your real work, a workbook and a knowledge quest, days unlock in sequence.
Lean Thinking on a Modern Floor
Day 1 · 120 min · 8 sections
- Map value streams
- Spot waste like a pro
Hover or tap for details
Lean Thinking on a Modern Floor
- Map value streams, Trace how work actually moves from supplier to customer, not how it's supposed to.
- Spot waste like a pro, Use the DOWNTIME framework to find at least three money leaks in any process.
- Measure what matters, Translate lean principles into metrics that matter to your leadership.
- Build improvement habits, Start small with daily waste walks that stick, even in busy plants.
Value Stream Mapping Basics
Day 2 · 120 min · 8 sections
- Map your value stream
- Spot the waste
Hover or tap for details
Value Stream Mapping Basics
- Map your value stream, Draw a current state map that shows material and information flow from raw material to customer delivery.
- Spot the waste, Use the DOWNTIME framework to identify the 8 wastes in your map and rank them by impact.
- Calculate the VSM metrics, Measure and calculate cycle time, lead time, and value-add ratio to quantify improvement opportunities.
- Future state vision, Design a future state map that cuts waste and improves flow with specific changes.
The DOWNTIME Waste Walk
Day 3 · 120 min · 8 sections
- Master DOWNTIME
- Walk the floor
Hover or tap for details
The DOWNTIME Waste Walk
- Master DOWNTIME, Recognize all 8 wastes by name and real examples from manufacturing floors.
- Walk the floor, Execute a structured waste walk that finds 3-5 real wastes per area in under 30 minutes.
- Scorecard wastes, Prioritize findings using the Waste Impact Scorecard to focus on high-impact fixes.
- Build the habit, Install a daily 15-minute waste walk ritual that survives busy weeks.
Finding the True Bottleneck
Day 4 · 120 min · 8 sections
- Identify bottlenecks
- Measure constraint impact
Hover or tap for details
Finding the True Bottleneck
- Identify bottlenecks, Use cycle time analysis to find the constraint that determines your factory's output.
- Measure constraint impact, Calculate how much bottleneck improvements boost overall throughput with real math.
- Prioritize improvements, Rank potential fixes by impact on flow and cost to implement.
- Create a plan, Build a 30-day bottleneck-busting action plan with clear milestones.
5S That Actually Sticks
Day 5 · 120 min · 8 sections
- 5S that lasts
- Red tag zone
Hover or tap for details
5S That Actually Sticks
- 5S that lasts, Implement Sort, Set in Order, Shine, Standardize, Sustain with real workplace examples that survive the first week.
- Red tag zone, Identify what stays, goes, or needs investigation with a clear process anyone can follow.
- Visual standards, Create simple, visual standards that show the correct state without needing words.
- 5S habit loop, Build a 5-minute daily and 20-minute weekly routine that becomes as automatic as coffee.
Standard Work Documentation
Day 6 · 120 min · 8 sections
- Capture current state
- Identify improvement points
Hover or tap for details
Standard Work Documentation
- Capture current state, Document exactly what happens now , no idealization, just facts of the work.
- Identify improvement points, Spot the steps that waste time or create variation in daily routines.
- Write standard work, Create a visual document with steps, timing, and quality checks that anyone can follow.
- Implement and audit, Roll out standard work with a simple audit cycle that measures adoption and effectiveness.
The Kanban Pull System Starter Kit
Day 7 · 120 min · 8 sections
- Size Kanban cards
- Apply the one rule
Hover or tap for details
The Kanban Pull System Starter Kit
- Size Kanban cards, Calculate the right number of cards using lead time and demand variation.
- Apply the one rule, Produce only what's consumed , no exceptions, no forecasts.
- Map the flow, Identify the perfect spot to place cards to maximize flow and minimize inventory.
- Measure the system, Track card cycle time and inventory turns to prove the system works.
SMED Changeover Race
Day 8 · 120 min · 8 sections
- Separate internal/external
- Streamline changeovers
Hover or tap for details
SMED Changeover Race
- Separate internal/external, Distinguish setup steps that require machine downtime from those that don't.
- Streamline changeovers, Convert external steps to wherever possible, cutting changeovers by half.
- Measure accurately, Time each step precisely to identify true bottlenecks, not just loud ones.
- Run a workshop, Facilitate a SMED Changeover Race with your team, using a structured format that delivers results.
Quality: Pareto & Root Cause with AI
Day 9 · 120 min · 8 sections
- Prioritize with Pareto
- Deep-dive with 5 Whys
Hover or tap for details
Quality: Pareto & Root Cause with AI
- Prioritize with Pareto, Use the 80/20 rule to spot which defects cost the most and deserve your attention first.
- Deep-dive with 5 Whys, Peel back layers of symptoms to find the true root cause that stops problems coming back.
- AI-assisted analysis, Train AI models to spot patterns in quality data humans miss and suggest countermeasures.
- Countermeasure design, Build testable solutions that prevent recurrence, not just quick fixes.
TPM & Maintenance Basics
Day 10 · 120 min · 8 sections
- Autonomous maintenance
- OEE mastery
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TPM & Maintenance Basics
- Autonomous maintenance, Shift routine checks from technicians to operators who know the machine best.
- OEE mastery, Calculate Overall Equipment Effectiveness and spot hidden losses in plain sight.
- Preventive vs predictive, Schedule maintenance that stops problems before they stop production.
- Human-centered TPM, Design machine care that builds skill, pride, and ownership.
Daily Tier Meetings & Escalation
Day 11 · 120 min · 8 sections
- Structure tier meetings
- Master the escalation ladder
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Daily Tier Meetings & Escalation
- Structure tier meetings, Build a 3-tier system that aligns daily work with weekly reviews and monthly strategy.
- Master the escalation ladder, Apply the 4-Escalation Levels to push problems upward only when they belong there.
- Drive accountability, Turn meeting minutes into clear ownership with the RACI Matrix on the floor.
- Make meetings stick, Install a weekly tier rhythm that survives production pressures and actually moves the needle.
Visual Management & Andon
Day 12 · 120 min · 8 sections
- Design visual dashboards
- Master the andon cord
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Visual Management & Andon
- Design visual dashboards, Build boards that scream when something is wrong without anyone needing to ask.
- Master the andon cord, Pull it early, pull it proud , stopping production to prevent bigger losses.
- Map information flow, Connect what happens on the line to what leaders see in real time.
- Measure what matters, Track the right metrics that drive improvement, not just activity.
AI on the Line: Logs, Predictions, Reports
Day 13 · 120 min · 8 sections
- Read AI logs
- Build prediction models
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AI on the Line: Logs, Predictions, Reports
- Read AI logs, Translate machine output into human questions with the Log Translation Matrix.
- Build prediction models, Create a simple forecast in Sheets that flags future bottlenecks with 24 hours' notice.
- Design reports that drive action, Structure a 30-second scan report that answers three questions: what's broke, why, and what now.
- Install guardrails, Set boundaries so AI never replaces human judgment on the floor.
Sustaining Kaizen: The Improvement Habit
Day 14 · 120 min · 8 sections
- Design your rhythm
- Spot the fade points
Hover or tap for details
Sustaining Kaizen: The Improvement Habit
- Design your rhythm, Map improvement activities to your energy levels and work cycles to create a sustainable pace.
- Spot the fade points, Identify when kaizen initiatives typically die and install countermeasures before they happen.
- Make it visible, Create a personal dashboard that tracks progress and creates gentle pressure to maintain momentum.
- Install the habit, Build a weekly improvement calendar that survives quarter-end and crunch periods.
Capstone: Your Smart Factory Roadmap
Day 15 · 120 min · 8 sections
- Map your current state
- Prioritize quick wins
Hover or tap for details
Capstone: Your Smart Factory Roadmap
- Map your current state, Create a detailed snapshot of your factory's current Lean maturity and AI readiness.
- Prioritize quick wins, Identify and sequence the 3-5 highest-impact improvements you can implement in the next 90 days.
- Design your future state, Build a visual blueprint of your Smart Factory with specific AI integrations for quality, maintenance, and flow.
- Build your execution plan, Create a 90-day timeline with metrics, milestones, and escalation paths for each improvement.
Frequently Asked Questions
Tools you will master
ZLearning Faculty
ZLearning faculty, every journey is built on real corporate workflows: reports, pipelines, decks and decisions, not theory.
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Join the learners turning AI into daily, measurable output. One payment, every prompt, workbook, download kit and your certificate included.
Secure checkout via Stripe · lifetime access · Digital product, non-refundable once delivered unless the course differs from this page · Refund policy