Achieving Operational Excellence in the Process Industry

Introduction:

The process industry is a capital-intensive sector facing intense global competition and high-risk operations. In such a challenging environment, process companies must prioritize enhancing operational performance to survive and grow.

The “Operational Excellence in the Process Industry” program is designed to identify key building blocks of operational excellence and assist delegates in developing a coherent improvement plan tailored to the needs of the process industry. This course introduces new concepts and methods in a straightforward manner, enabling learners to apply these techniques effectively within their areas of responsibility.

For professionals aiming to advance their skills and leadership capabilities, pursuing a Master’s degree or certification in Operational Excellence can be transformative. This course serves as a foundational step for those interested in achieving higher certifications in operational excellence.

By improving operational efficiencies, reducing risks, and fostering a culture of continuous improvement, participants will be well-prepared for further studies and the pursuit of operational excellence certification.

Objectives:

Participants in this Operational Excellence in the Process Industry course will:

• Master best practice techniques related to operational excellence.
• Identify and understand both technical and human factors and their implications for planning and operations.
• Develop and implement a targeted action plan to address specific risk areas with best practices.
• Create a practical plan to integrate proposed technologies into operations and evaluate their impact on the organization.

Training Methodology:

• Case Studies
• Workshops
• Simulations
• Group Discussions
• Role Playing
• Interactive Exercises
• Scenario Analysis
• Expert Panels
• Project-Based Learning

Course Outline:

Unit 1: Safety

• Making safety a priority
• Behavioral Safety: People at Risk
• Risk evaluation systems
• Understanding work permits, hazard and operability study (HAZOP), and other standard procedures
• Incident Investigation & Reporting: Analyzing Near Misses, Incidents & Accidents
• Developing a Complete Safety Management System

Unit 2: Continuity of Operations – Plant Reliability

• Managing operational risks and organizational structure
• Assessing vulnerability and resilience
• Enhancing reliability
• Supporting plant and equipment
• Formulating effective maintenance plans
• Implementing flexible manufacturing strategies

Unit 3: Quality

• Defining Quality Control Systems
• Managing Quality: Minimizing Loss and Waste
• Continuous Improvement Systems
• Quality Assurance Management
• Developing and adhering to Standard Operating Procedures (SOP)
• Enhancing Quality by Preventing Errors

Unit 4: Costing

• Implementing Costing Systems
• Lean Manufacturing Strategies
• Managing Inventory Systems
• Using a life cycle perspective for equipment selection
• Asset Management
• Best Practices: From Product to Process

Unit 5: People Management/Development

• Leadership and Enabling Involvement
• Managing Change Processes
• Human Resource Performance Management Frameworks
• Skill and Competency Development
• Issue Resolution and Management