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Course Overview and Strategic Context for Work-in-Process (WIP)

Program Introduction: Defining Work-in-Process (WIP) and Enterprise Relevance

End-to-End WIP Flow: From Material Release to Final Inspection and Acceptance

Designing and Controlling WIP Flow

Flow Design for WIP: Routing, Lot Sizing, and Buffer Strategy

Release and Authorization Policies for WIP Governance

Visual and Digital Control of WIP: MES/ERP, Kanban, and Real-Time Tracking

Quantitative WIP Analysis and Performance Optimization

Queueing, Variability, and Capacity: Modeling WIP to Stabilize Lead Time

Diagnosing and Improving WIP Performance

Accounting, Valuation, and Compliance for WIP

WIP Valuation and Financial Reporting

Operational-Financial Alignment: Policies, Metrics, and Incentives

Risk, Resilience, and Enterprise Integration of WIP

Resilient WIP Systems Under Uncertainty

Enterprise Integration: WIP Across Operations, Quality, Supply Chain, and Finance

Capstone and Knowledge Check

Capstone Synthesis: Architecting an End-to-End WIP Operating Model

Quiz 1: WIP Fundamentals and Flow

Quiz 2: Release Policies and Governance

Quiz 3: Routing, Lot Sizing, and Buffers

Quiz 4: Digital and Visual Management of WIP

Quiz 5: Queueing and Variability

Quiz 6: WIP Diagnostics and Improvement

Quiz 7: WIP Valuation and Accounting

Quiz 8: Operational-Financial Alignment

Quiz 9: Resilience and Risk in WIP

Quiz 10: Enterprise Integration and Capstone Review

End-to-End Work-in-Process Mastery: Flow, Governance, and Visibility is a practitioner-built course for leaders who need to accelerate throughput, protect lead time, and align operations with financial reality. From the moment raw material is authorized for release to final inspection and acceptance, Work-in-Process (WIP) is where flow either wins or fails. This program gives you the playbook to design, control, and continuously improve WIP across factories, labs, repair depots, and high-mix job shops. You will learn to map value streams, size buffers, set smart release policies (CONWIP, kanban, drum-buffer-rope), and integrate MES/ERP, dashboards, and traceability so every unit has a digital heartbeat. Go beyond theory with quantitative methods—Little’s Law, queueing, variability, and capacity modeling—to stabilize lead time and optimize WIP caps. Translate improvements into financial outcomes through correct valuation, roll-forwards, and governance, ensuring audit-ready controls and cross-functional accountability. Finally, build resilience for uncertainty with scenario-driven WIP posture and enterprise integration across operations, quality, supply chain, and finance. If you own service levels, cash, or capacity, this is your end-to-end system for confident WIP decisions.

End-to-End Work-in-Process Mastery: Flow, Governance, and Visibility

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            <p>Work-in-process is the heartbeat of operational performance, linking material release to final acceptance while tying together flow efficiency, cash utilization, service levels, and quality. This course provides a rigorous, end-to-end framework for mastering WIP as an enterprise asset—designing flow, governing release, and enabling real-time visibility. You will examine the full WIP lifecycle from authorization, routing, and processing through inspection, rework, and disposition, including integration points with BOMs, routings, resources, and semifinished components. Emphasis is placed on how WIP integrates with operations, quality, finance, and supply chain objectives to stabilize lead times, safeguard capacity, and strengthen financial stewardship.</p>
<p>Designed for supply chain and operations leaders, the program progresses from strategic context to quantitative control. You will learn to map value streams, set routing standards, determine lot sizing and decoupling points, and architect buffer strategies such as cycle stock, safety WIP, and supermarkets. Governance is addressed through disciplined release policies—CONWIP, kanban, and drum-buffer-rope—supported by escalation triggers, control limits, and audit trails that balance service levels with cash and capacity constraints. The course then advances to digital and visual management using MES/ERP integration, e-kanban signals, IoT tracking, and dashboards that surface WIP age, queue length, flow efficiency, bottlenecks, traceability, and genealogy for defect containment.</p>
<p>To stabilize lead time and throughput, you will apply quantitative methods including Little’s Law, variability analysis (arrival, process, setup), and capacity modeling to set optimal WIP caps and buffer placement. Practical diagnostics—heat maps, WIP age analysis, and queue profiles—are paired with improvement levers such as SMED, standard work, constraints management, and quality at the source, with patterns differentiated for high-mix/low-volume and high-volume/low-mix environments. Financial rigor is built in through WIP valuation and reporting across standard, actual, and weighted-average costing; roll-forwards, variances, reconciliation to the general ledger; and audit and regulatory controls.</p>
<p>The curriculum further aligns operational policies with financial exposure, defining KPIs such as WIP turns, age, yield, rework rate, and cost-to-complete, and establishing cross-functional governance with clear ownership, segregation of duties, and integrated physical/digital counts. Resilience is addressed through scenario planning, buffer design for uncertainty, and WIP posture choices across make-to-order and make-to-stock strategies, alongside business continuity and obsolescence risk controls. Enterprise integration closes the loop by synchronizing production control with supply and demand, embedding quality workflows for nonconformance and quarantine, linking S&OP/IBP to WIP targets, and enforcing data governance for master data, UoM, serialization, and audit trails.</p>
<p>The capstone consolidates learning into an end-to-end WIP operating model: translating business strategy into WIP design and performance targets; defining release policies, routing standards, digital control mechanisms, and accounting linkages; and setting control limits, escalation paths, and traceability requirements. You will also develop dashboards and review cadences that sustain continuous improvement and compliance. Knowledge checks throughout the program reinforce fundamentals of flow, governance, routing and buffers, digital management, queueing and variability, diagnostics, valuation, alignment, resilience, and enterprise integration—preparing you to architect and run high-performance WIP systems.</p>
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