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Master’s in Operational Excellence & Lean Engineering for High-Variability Environments

Online master's programme of 1,900 hours in operational excellence and lean engineering for high-variability environments. 12 modules covering Factory Physics, high-mix lean, QRM and POLCA, theory of constraints, scheduling, short-run Six Sigma, SMED, daily management, simulation, digitalisation and supply chains, with an assigned technical tutor.

Duration1900 h
ModeOnline
LanguageEnglish
Start datesSet by the faculty
AwardSEIUM Institute diploma
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Learning outcomes

What you will be able to do

01

Quantify variability and its effect on lead times and inventory with Factory Physics.

02

Adapt lean tools to high-mix, low-volume environments.

03

Apply QRM and POLCA to reduce manufacturing critical-path time.

04

Manage constraints using the theory of constraints and DBR.

05

Control short-run processes with appropriate statistical techniques.

06

Validate flow redesigns using discrete-event simulation.

07

Implement sustainable daily management and operational excellence systems.

Profile

Who it's for

  • Operational excellence managers.
  • Lean engineers working in high-mix environments.
  • Six Sigma Black Belts.
  • Production planners.
  • Process engineers.
  • Continuous improvement consultants.
  • Engineering or science graduates seeking to enter the capital goods sector.
Standards & tools

What you'll work with

  • ISO 22400-2:2014 (KPIs for manufacturing operations management)
  • ISO 13053-1:2011 (Six Sigma DMAIC methodology)
  • ISO 7870-2:2023 (Shewhart control charts)
  • ISO 9001:2015 (quality management systems)
  • ISO 22514-2 (process capability and performance)
  • ISO 18404:2015 (competencies for Six Sigma and lean implementation)
  • IEC 62264-1 (enterprise-control system integration)
  • Minitab
  • FlexSim
  • Celonis
  • Siemens Opcenter APS
  • Simio
Syllabus

12 modules · 1900 h

  1. 1.1Demand, mix and process variability
  2. 1.2High-mix, low-volume environments
  3. 1.3Factory Physics and the laws of variability
  4. 1.4Little's Law and the WIP–lead time relationship
  5. 1.5Kingman's equation and utilisation
  6. 1.6Coefficients of variation of arrivals and processes
  7. 1.7Make-to-order versus make-to-stock
  8. 1.8The cost of product complexity
  9. 1.9Measuring variability on the shop floor
  10. 1.10Lab: operating curves with Factory Physics
  1. 2.1Limitations of classic lean in high-mix settings
  2. 2.2Variable takt and production windows
  3. 2.3Product families and PQ-PR analysis
  4. 2.4Flexible cells and multi-skilling
  5. 2.5Heijunka with variable mix
  6. 2.6Kanban for slow-moving part numbers
  7. 2.7CONWIP and generic cards
  8. 2.8Lean in engineer-to-order
  9. 2.9Work standards with high variety
  10. 2.10Workshop: product families with a product-process matrix
  1. 3.1Rajan Suri's QRM philosophy
  2. 3.2The MCT (manufacturing critical-path time) metric
  3. 3.3QRM cells and focused organisation
  4. 3.4The POLCA material control system
  5. 3.5Planned spare capacity
  6. 3.6Lead time reduction in technical offices
  7. 3.7Comparing QRM and lean
  8. 3.8Implementing QRM in SMEs
  9. 3.9Responsiveness indicators
  10. 3.10Practical: MCT map of a customer order
  1. 4.1The five focusing steps
  2. 4.2Drum-buffer-rope (DBR)
  3. 4.3Buffer management and penetration
  4. 4.4Throughput accounting
  5. 4.5Market and policy constraints
  6. 4.6Critical chain in projects
  7. 4.7Current and future reality trees
  8. 4.8TOC in replenishment and distribution
  9. 4.9Combining TOC, lean and Six Sigma
  10. 4.10Lab: DBR simulation in a job shop
  1. 5.1Finite-capacity planning
  2. 5.2Job shop scheduling
  3. 5.3Priority and dispatching rules
  4. 5.4Scheduling with genetic algorithms
  5. 5.5Demand-driven planning with DDMRP
  6. 5.6Buffer positioning
  7. 5.7Managing rush orders
  8. 5.8Configurators and variable bills of materials
  9. 5.9Resources shared across families
  10. 5.10Case study: scheduling a boiler-making shop
  1. 6.1Measurement system analysis
  2. 6.2Statistical control for short runs
  3. 6.3Z-MR charts and standardised charts
  4. 6.4Factorial design of experiments
  5. 6.5Robustness and the Taguchi method
  6. 6.6Variance components
  7. 6.7Capability across multiple part numbers
  8. 6.8Lean Six Sigma in short series
  9. 6.9Root cause analysis tools
  10. 6.10Practical: short-run SPC with standardised charts
  1. 7.1Advanced SMED in high mix
  2. 7.2Sequencing to minimise set-ups
  3. 7.3Modular and standardised tooling
  4. 7.4Flexible automation and cobots
  5. 7.5Additive manufacturing of tooling
  6. 7.6Multi-skilling and the skills matrix
  7. 7.7Volume and working-time flexibility
  8. 7.8Modular product design
  9. 7.9Postponement and late differentiation
  10. 7.10Workshop: changeover reduction on a press brake
  1. 8.1The Shingo and EFQM excellence models
  2. 8.2Daily management and tiered meetings
  3. 8.3Visual management of variability
  4. 8.4A3 problem solving
  5. 8.5Improvement kata and coaching kata
  6. 8.6Lean leadership and gemba
  7. 8.7Deploying standards
  8. 8.8Layered process audits
  9. 8.9Excellence indicators
  10. 8.10Case study: daily management in a plant
  1. 9.1Discrete-event simulation
  2. 9.2Distributions for modelling variability
  3. 9.3Validating simulation models
  4. 9.4Experimentation and scenarios
  5. 9.5Simulation-based optimisation
  6. 9.6Flow digital twins
  7. 9.7Queueing networks
  8. 9.8Visualising results
  9. 9.9Simulation for cell design
  10. 9.10Lab: simulation of a flexible cell
  1. 10.1MES and real-time tracking
  2. 10.2Automatic capture of stoppages and OEE
  3. 10.3Process mining of production orders
  4. 10.4Artificial intelligence in planning
  5. 10.5Electronic kanban and digital signals
  6. 10.6IIoT and machine sensing
  7. 10.7Flow dashboards
  8. 10.8Integrating ERP and advanced planning
  9. 10.9Return on digital investment
  10. 10.10Practical: process mining of production orders
  1. 11.1Supply chain segmentation
  2. 11.2Erratic demand and probabilistic forecasting
  3. 11.3Safety stock with variable lead times
  4. 11.4Supplier collaboration in high mix
  5. 11.5Internal logistics and line-side supply
  6. 11.6Purchasing for engineer-to-order
  7. 11.7Long lead-time components
  8. 11.8ATP and CTP delivery promising
  9. 11.9Resilience to demand peaks
  10. 11.10Case study: segmentation of a spare parts supply chain
  1. 12.1Selecting the plant or process for study
  2. 12.2Characterising the variability
  3. 12.3Diagnosis of flow and lead time
  4. 12.4Design of the production control system
  5. 12.5Improvements with lean, QRM or TOC
  6. 12.6Validation through simulation
  7. 12.7Implementation and change management
  8. 12.8Evaluation of results and indicators
  9. 12.9Master's Thesis report
  10. 12.10Master's Thesis: defence before a panel
Methodology, software & labs

How you'll learn

A 100% online programme on the SEIUM campus, with downloadable material, recorded classes and an assigned technical tutor. There are no fixed timetables: you progress at your own pace within each intake, so the programme fits around your job.

Each module combines theory, guided reading of the original standard and applied exercises. The working software is Minitab, FlexSim, Celonis, Siemens Opcenter APS and Simio, in free, academic or evaluation versions. Exercises are based on real procedures: designing a POLCA system in a job shop, simulating a drum-buffer-rope system and statistical control of short runs. Assessment is continuous by module, plus the final Master's Thesis.

Standards covered: ISO 22400-2:2014, ISO 13053-1:2011, ISO 7870-2:2023, ISO 9001:2015, ISO 22514-2, ISO 18404:2015, IEC 62264-1.

Assigned technical tutor:every module ends with a deliverable that your tutor marks individually.
Standards-based learning:guided reading of ISO 22400-2, ISO 13053-1, ISO 7870-2 and ISO 22514-2 applied to real cases, not as a theoretical annex.
Industry software:Minitab, FlexSim, Celonis, Siemens Opcenter APS and Simio, in free, academic or evaluation versions.
Master's Thesis with defence:a production control and flow redesign for a high-variability plant, validated by simulation, defended before a panel.
Flexible format:100% online, no fixed timetables, compatible with full-time work.
Capstone project

Build it end to end

Your final project follows the real engineering workflow, step by step, reviewed by your tutor.

Variability characterisation
Build Factory Physics operating curves to quantify variability, WIP and lead time.
POLCA and MCT design
Map the MCT of a customer order and design a POLCA control system for a job shop.
DBR simulation
Simulate a drum-buffer-rope system and set up buffer management.
Short-run SPC
Implement statistical control of short runs using standardised charts.
Master's Thesis
A production control and flow redesign for a high-variability plant, defended before a panel.
Career opportunities

Where this takes you

Operational excellence managerLean engineerSix Sigma Black BeltProduction plannerProcess engineerContinuous improvement consultant
Admissions & scholarships

Requirements

  • University degree in engineering, science or architecture, or equivalent demonstrable professional experience.
  • Internet connection and a computer able to run the programme software.
  • English sufficient to read technical standards.

Ready to start?

Send your application today. Our admissions team replies within 72 hours with your study plan and funding options.

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FAQ

Frequently asked questions

The programme totals 1,900 hours over 12–14 months. You set your own pace within each intake, and your tutor helps you plan the workload around your job.

You work with Minitab, FlexSim, Celonis, Siemens Opcenter APS and Simio, using free, academic or evaluation versions. Your tutor indicates the free alternative wherever one exists.

A SEIUM Institute diploma, awarded on passing the continuous assessment and the Master's Thesis. It is SEIUM's own qualification, not an official state degree; its recognition depends on the programme completed and the regulations of each country.

Yes. Modules passed in a course or postgraduate diploma in the same area are recognised in the higher programme. Ask about the recognition policy when you enrol.

A university degree in engineering, science or architecture, or equivalent professional experience, plus a computer able to run the programme software and English sufficient to read technical standards.

Start dates are set by SEIUM's faculty for each intake. Our admissions team will confirm the next available date when you apply.

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