Unlocking Opertational Efficiency Training

Industrial engineering has had several developments in the last hundred years. Most recently, LEAN has supported companies in understanding and implementing tools from the Toyota Production System.  Continuous Process Improvement (CPI) has contributed new understandings of what makes an employee successful and the importance of including the frontline workforce in process improvement.

This training program teaches you the most commonly used LEAN tools, the ones that have a significant impact on any company. You’ll do exercises that apply these tools to your business.  You’ll learn how to use Gemba boards and the importance of employee engagement.  Our goal is to provide hands-on learning so that you’re confident using LEAN and CPI principles in your work.

The Unlocking Operational Efficiency training program consists of eight 2-hour modules. Completion of all modules required for achieving Process Improvement green belt certificate.

Module 1: Get to Root Cause

Play the “Get to Root Cause” game to develop an appreciation for root cause analysis (RCA), and to learn how to use common RCA tools such as Fishbone, 5 Whys?, etc.

Module 2: Organize Your Workspace

Learn how to use 5S and Visual Management to deliver more disciplined and organized maintenance trucks and storage rooms. Objective is to increase productivity, improve safety, and reduce tools/material costs.

Module 3: See the Process

Participate in a process mapping exercise to understand what you should get out of a process mapping session, and how to achieve it. Also learn about SIPOC, Customer vs. Business vs. Non Value Added, and Value Stream Mapping.

Module 4: Eliminate Waste

LEAN is the optimal starting point for most productivity programs. LEAN focuses on low-hanging fruit by identifying “waste” and applying the various LEAN tools to get rid of the waste.  Learn about Line Balancing, Spaghetti Diagrams, Standard Work, etc.

Module 5: Increase Overall Equipment Effectiveness

Overall Equipment Effectiveness (OEE) is a widely used metric in the process industry to drive continual improvement of the percentage uptime for automation. Learn to effectively and efficiently collect and interpret data on both equipment breakdown and model changeover activities.  Also learn about the SMED approach to set up reduction.

Module 6: Increase Employee Engagement

Labor is becoming scarcer. Automation is a long-term expensive option, and visas are ineffective if the trend of less people desiring to migrate to be farm workers continues.  Learn instead to get more from your existing labor pool through a respectful intrinsic motivation based culture

Module 7: Design Cost Effective Processes and Distribution Networks

Simulation & Optimization are tools that work together to address challenging system and network problem. Simulation allows you to build a computer replica of your proposed process/facility, and then experiment with different ways to run it.  Optimization creates a solution that satisfies a critical set of constraints.

Module 8: Advanced Operational Improvement Tools

This last module covers advanced topics like: Kaizens, Gemba Boards, using control charts of leading indicators to drive process improvement efforts, Pull Systems, and Design of Experiments (DOE).  Also includes a brief review of the history of the process improvement profession.

Program Fees

This training program is delivered on-site over an eight+ week period. Client needs to provide training location and all associated visual aid mechanisms (projection unit, flip charts, markers, etc.).  The investment required is $8,000 plus travel expenses, and the number of participants suggested is 6-10 people.

On-site Coaching Option

In addition to the on-site delivery of this training program, we offer an option where we also provide additional on-site coaching to participants on how to apply the principles taught to a specific work-related problem they are working on.