Professional Training & Certification

Lean Manufacturing Through Interactive Simulation

A 12-session program that teaches the real mathematics behind production flow — variability, constraints, pull systems, buffer sizing, and financial impact. Every concept is proven hands-on through a dice simulator that mirrors real factory behavior, then directly connected to professional consulting practice.

Built for operators, supervisors, engineers, and managers who need to understand why lean works — not just follow a checklist.

Request Enrollment →View Full Curriculum
📐
Math-groundedTheory of Constraints + Queuing
🎲
Hands-on simulatorDice game proves every concept
🏭
Real ROI examplesFactory case studies each session
🎓
Certified on completionCertified Flow Architect credential
12
Structured Sessions
4
Learning Parts
Plain
Language Throughout
CFA
Certificate on Completion
Learning Outcomes

What you will be able to do

By the end of this program every student will have practical, measurable skills — not just awareness of terms.

01
Diagnose variabilityExplain why variability — not worker speed — is the primary cause of production loss, and quantify it using standard deviation and CV.
02
Find and fix the constraintIdentify the system bottleneck using the Five Focusing Steps and apply exploit/subordinate/elevate logic to improve throughput.
03
Design balanced flowBuild pull systems with mathematically sized WIP limits using Little's Law and the Kingman VUT equation.
04
Optimize operationsCalculate optimal buffer sizes, batch quantities, and setup time reduction targets using Economic Batch Quantity and SMED staging.
05
Build the business caseBuild a financial case using Throughput Accounting (T, I, OE) with ROI and payback calculations that leadership will approve.
06
Apply professional toolsTranslate simulation results directly into LTOCOR network configurations and VSFlow production monitoring dashboards.
Full Curriculum

12 sessions across 4 parts

Each session builds on the last. Students cannot skip ahead — understanding is sequential and cumulative.

Part 1FoundationsSessions 1 – 3
1
Understanding Variability
Why real production is unpredictable. Standard deviation, coefficient of variation, and the gap between average and actual output. The dice as a factory model.
Simulator
2
Finding the Bottleneck
Theory of Constraints, the Five Focusing Steps, and why improving non-constraints wastes money. The water slide analogy and system throughput math.
Theory
3
Balanced Flow vs. Balanced Line
Why balancing capacity is the wrong goal. Little's Law, Kanban signals, and the shift from capacity management to flow control. Proving why WIP limits outperform line balancing.
Simulator
Part 2Controlling FlowSessions 4 – 6
4
WIP Limits (Kanban)
How WIP limits self-regulate flow. The knee of the curve, finding the optimal buffer size, and the Green/Yellow/Red zone management model.
Simulator
5
Pull Systems
Push vs. pull logic, Drum-Buffer-Rope scheduling, and mathematical proof — using replication data — that pull + WIP limits outperforms push in every metric.
Simulator
6
Buffer Sizing
Three buffer types (Constraint, Assembly, Shipping), the Kingman VUT equation, and sizing buffers to actual variability rather than gut feel or tradition.
Theory
Part 3Reducing WasteSessions 7 – 9
7
Setup Time Reduction (SMED)
Internal vs. external setup, the four SMED stages, and calculating the financial return of setup reduction projects. Pit-stop thinking applied to factory changeovers.
Finance
8
Batch Size Optimization
The batch size / WIP trade-off, Economic Batch Quantity (EBQ), and why SMED shifts the optimal batch size. Finding the sweet spot between setup frequency and inventory.
Simulator
9
Variability Reduction
Die trimming as a model for standard work and TPM. The Kingman proof: halving CV reduces queue time by 75%. What standard work is really worth in dollars.
Simulator
Part 4Measuring SuccessSessions 10 – 12
10
Reliability and Predictability
Reliability % as the key customer-facing metric. Statistical confidence through replications. Mean vs. standard deviation and what they mean for delivery promises.
Theory
11
Financial Impact
Throughput Accounting (T, I, OE), ROI calculation, payback period, and building the business case for lean investment that management will fund.
Finance
12
Continuous Improvement
PDCA cycle, ongoing buffer management, and applying everything learned to your own production data using LTOCOR and VSFlow. Commitment to a first real improvement project.
Simulator
Session Structure

Every session follows five steps

Consistent structure means students always know where they are and what comes next.

💬
Step 1
The Analogy
An everyday story that introduces the concept before any technical language
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Step 2
The Theory
The mathematics and principles, with key terms and formulas explained simply
🎲
Step 3
The Simulation
A guided activity using the interactive dice simulator to prove the theory with real data
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Step 4
The Case Study
Real factory examples with before/after metrics and financial outcomes
✅
Step 5
The Assessment
Quiz questions that confirm understanding before moving to the next session
How We Deliver

Choose the format that fits your team

Both formats use the same curriculum, simulator, and certification. The difference is pace, setting, and hands-on engagement.

Recommended Start
🏭
On-Site Workshop
At your facility — using your real production floor

An AMC consultant delivers the full program at your facility. Simulation scenarios are configured to reflect your actual value streams, cycle times, and constraint data. Teams learn together and immediately apply the concepts to real problems they recognize.

  • Delivered across 2–3 days or weekly half-day sessions
  • Simulator pre-loaded with your production data
  • Constraint analysis of your actual floor layout
  • Group scenario comparison exercises
  • On-site support for first improvement project
  • Certificate awarded to each completing participant
💻
Online Training
Self-paced with live instructor check-ins

Students work through sessions at their own pace inside the members-only training portal. Each session includes the simulator embedded directly in the course, guided activities, and a quiz gate before the next session unlocks. Live Q&A sessions available monthly.

  • Access for 90 days from enrollment
  • Simulator embedded in every session
  • Progress tracking and session gating
  • Monthly live Q&A with AMC instructor
  • Discussion forum with peers
  • Certificate awarded on quiz completion
Pricing

Straightforward pricing, serious ROI

Every option includes the full 12-session curriculum, simulator access, and the Certified Flow Architect credential. Organizations typically recover training costs within the first improvement project.

Online
Individual
$497
per person  ·  90-day access

Full self-paced online access for a single learner. Ideal for individuals seeking professional development or managers wanting to preview the curriculum before bringing it to their team.

  • All 12 sessions unlocked sequentially
  • Simulator embedded in portal
  • Monthly live Q&A sessions
  • Certified Flow Architect credential
  • Custom production scenarios
  • On-site delivery
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Most Popular
Online
Team (5–10)
$297
per person  ·  volume pricing

The same full program for a team. Shared discussion forum so your people learn together even while working individually. 5–10 participants. Includes one group Q&A session dedicated to your team.

  • All 12 sessions, shared progress dashboard
  • Simulator embedded in portal
  • Dedicated team Q&A session (1 hr)
  • Certified Flow Architect for each completer
  • Group discussion board
  • On-site delivery
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On-Site Workshop
At Your Facility
$4,500
per day  ·  up to 10 participants

AMC delivers the full program at your facility with your production data built into the simulation scenarios. Two-day workshop covers all 12 sessions with exercises on your value streams. Travel billed separately.

  • Full 2-day on-site delivery (all 12 sessions)
  • Simulator pre-loaded with your data
  • Constraint analysis of your floor layout
  • Certified Flow Architect for all participants
  • 30-day follow-up support included
  • Portal access add-on available (+$150/person)
Request a Quote

All prices in USD. Contact us to discuss multi-site or enterprise arrangements.

🎓
Certified Flow Architect (CFA)

Students who complete all 12 sessions and pass the session assessments receive the Certified Flow Architect designation from Albert Mureen Consulting. The credential signals demonstrated understanding of flow theory, constraint management, Throughput Accounting, and simulation-based analysis — skills directly applicable to LTOCOR and VSFlow professional practice.

Ready to understand why your factory behaves the way it does?

Submit an enrollment request and we will contact you within 24 hours with program details, scheduling, and the format that best fits your team.

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