Operational Excellence in Manufacturing

Introduction:

Building Manufacturing Excellence into the Process Industry aims to describe the key aspects of operational excellence and integrate them into a comprehensive improvement program for the process industry. This course introduces the latest tools and techniques in a simplified manner to enable participants to operationalize them effectively. In the Manufacturing Excellence course, participants will learn methodologies and best practices to elevate their businesses to the forefront of global manufacturing.

Each unit equips practitioners with models and systems that support integrated processes for operational improvements, empowering professionals to perform significantly better. By studying manufacturing excellence, participants will gain the skills needed to become change agents in their professional practice.

Objectives:

At the end of this Manufacturing Excellence course, participants will be able to:

• Implement quality-oriented transformations using Total Quality Management (TQM) within their organization.
• Benchmark manufacturing systems against best practices and design a best-in-class quality management system.
• Evaluate various concepts, standards, models, and techniques to design efficient and effective manufacturing systems.
• Identify and eliminate non-value-adding activities that hinder material flow and processes in manufacturing.
• Define key concepts and principles of quality management.
• Apply problem-solving techniques and process improvement methods.

Training Methodology:

• Expert-led interactive lectures
• Case studies and real-world applications
• Team collaboration
• Learning by doing
• Role plays
• Active problem-solving exercises
• Continuous improvement tool tutorials
• Process creation exercises
• Lean production tools
• Experience sharing of best practices

Course Outline:

Unit 1: Operational Excellence for Beginners:

• Operational Excellence: Identifying and addressing gaps in the corporation
• Becoming a problem solver: Root cause problem-solving principles
• Waste elimination demystified
• Standard work and process mapping

Unit 2: The Heart of Operational Excellence:

• Workshop: Lean Principles with the Lean Manufacturing Simulation Game
• Value Stream Management
• 5 Why Technique
• 5S & Visual Controls in the Workplace
• Set-up Time Reduction
• Preventive Maintenance in Total Quality Management
• Poka Yoke system
• Structure and management of Kaizen activities
• Floating Cell Manufacturing

Unit 3: Overview of Quality Systems:

• Quality system fundamentals
• Quality System Primer for professionals in Quality Management
• Internal Auditor for Quality Management System:
  • ISO 9001: 2015
  • AS9100 Rev D
  • IATF 16949: 2016
  • ISO 13485: 2016

Unit 4: Management System as a Core Instrument of Quality Systems:

• Quality planning in product development
• Disposables part approval process
• Failure Mode and Effects Analysis (FMEA)
• Measurement System Evaluation
• Statistical Process Control (SPC)

Unit 5: Quality Inspector/Quality Technician:

• Problem identification and root cause analysis
• Statistical Process Control (SPC)
• Gage and Measurement System Analysis (if applicable)