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Course Orientation and Foundational Concepts of Work in Process (WIP)

Course Orientation: Objectives, Outcomes, and Assessment

Defining Work in Process (WIP) and Its Place in Value Streams

Flow Science and Queuing Theory Essentials for WIP

Diagnosing, Measuring, and Visualizing WIP

WIP Metrics: Selection, Definitions, and Calculation

Dashboards and Kanban: Making Work States and Queues Visible

Designing and Implementing WIP Control Systems

Setting Static and Dynamic WIP Limits with Pull Policies

Governance, Cadence, and Risk Controls for Predictable Flow

Integrating WIP into End-to-End Flow Architecture

Value Stream Mapping and Constraint Management with WIP

Economics of WIP: Cost of Delay, Service Levels, and Profitability

Leading Enterprise-Scale WIP Transformation

Operating Model, Portfolio Alignment, and Change Management

Capstone Application and Assessments

Capstone: Design a WIP Control System for a Target Value Stream

Quiz 1: WIP Foundations and Definitions

Quiz 2: Flow Science and Queuing Theory Basics

Quiz 3: WIP Metrics and Measurement

Quiz 4: Visualization and Kanban Design

Quiz 5: WIP Limits and Pull Policies

Quiz 6: Governance and Risk Controls

Quiz 7: Value Stream Mapping and Constraints

Quiz 8: Economics of WIP and Cost of Delay

Quiz 9: Enterprise Operating Model and Transformation

Quiz 10: Capstone Readiness and Integrated WIP Philosophy

Mastering WIP: Designing Predictable Flow Across Enterprise Value Streams is a practitioner-built course for leaders who must deliver faster, more reliably, and at lower cost across complex operations. Whether you run manufacturing lines, shared services, or software delivery, Work in Process (WIP) is the lever that governs speed, predictability, and profitability. This hands-on program demystifies WIP with clear definitions, flow science, and visual tools, then shows you how to set intelligent WIP limits, implement pull, and hardwire governance so you can stabilize throughput and shorten lead times at scale. You will learn to map value streams, expose queues and bottlenecks, and use dashboards, Kanban, and cumulative flow diagrams to manage aging work and risk. We connect WIP decisions to service levels, cost of delay, margin, and cash-to-cash impacts—translating flow into business results. The capstone challenges you to design a complete WIP control system for your target value stream, backed by economic rationale and measurable outcomes. If you are ready to replace chaos with clarity and create predictable flow across the enterprise, this course provides the blueprint, the metrics, and the cadences to make it real.

Mastering WIP: Designing Predictable Flow Across Enterprise Value Streams

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            <p>Mastering WIP: Designing Predictable Flow Across Enterprise Value Streams equips supply chain and operations leaders to diagnose, design, and govern work-in-process as a measurable, controllable lever for end-to-end performance. The course begins by establishing a precise definition of WIP—items started but not yet finished—and rigorously distinguishes it from inventory, backlog, cycle time, lead time, and throughput. Participants examine how WIP accumulates across states such as queued, active, blocked, review, test, and ready-to-ship, and then ground these concepts in the essentials of flow science. Using Little’s Law and queuing theory, you will analyze how variability, utilization, and batching drive WIP build-up, and compare push versus pull systems to understand the structural drivers of predictability and delay.</p>

<p>Building on this foundation, the program moves from measurement to management. You will select and compute practical metrics—WIP count, WIP limits, aging WIP, flow efficiency, arrival and departure rates—and visualize risk through percentiles to link aging to service levels and cost of delay. With dashboards, Kanban design, and cumulative flow diagrams, you will make queues, bottlenecks, blocked work, and expedite policies visible and actionable. The course then advances to architecting control systems: setting static and dynamic WIP limits, defining pull signals and replenishment cadences, and implementing classes of service to protect flow. Governance modules align intake with capacity, establish review cadences for blockers and aging WIP, and integrate quality controls to prevent hidden WIP.</p>

<p>At enterprise scale, you will integrate WIP into value stream architecture by mapping end-to-end flows to expose queues, rework loops, and handoffs, then sizing buffers around constraints to stabilize throughput while improving flow efficiency. Economic modules translate WIP decisions into financial outcomes, quantifying trade-offs among WIP, cycle time, and service levels, estimating cost of delay to guide prioritization and batch sizing, and linking policies to margins, working capital, and cash-to-cash cycles. The transformation segment frames an operating model spanning strategy, portfolio intake, and execution, supported by governance cadences, metrics, and cultural norms that sustain predictable flow.</p>

<p>Learning is reinforced through targeted quizzes on foundations, queueing, metrics, visualization, limits, governance, value stream mapping, and economics. The capstone challenges you to design a full WIP control system for a chosen value stream—manufacturing or knowledge work—by mapping current flow, measuring WIP, identifying constraints, computing flow efficiency, and proposing limits, pull policies, and governance with an explicit economic rationale. By the end, you will be able to convert WIP from a passive byproduct of work to an active control variable that improves service reliability, reduces lead times, and enhances profitability across enterprise value streams.</p>
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