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Operational Excellence in Manufacturing
course
IT Management and Cyber Security
Course Overview
In today’s dynamic manufacturing landscape, characterized by rising customer expectations, global competition, and the rapid integration of Industry 4.0 technologies, achieving mere efficiency is no longer sufficient for sustained success.
The Operational Excellence in Manufacturing Course provides a strategic framework to go beyond traditional practices, embedding a holistic culture of continuous improvement and innovation.
Operational Excellence (OpEx) is a management philosophy that ensures organizations consistently deliver superior value, eliminate waste, and drive sustainable performance across all levels. This course explores the integration of Lean and Six Sigma methodologies to streamline processes, enhance product quality, and minimize variability.
Participants will develop and implement robust performance measurement systems, foster effective leadership, and cultivate a culture of employee engagement and customer-centric thinking, ultimately building a more agile, resilient, and profitable manufacturing operation.
Course Objectives
By the end of this course, participants will be able to:
Understand the core principles and essential building blocks for achieving operational excellence in manufacturing.
Apply Lean and Six Sigma tools to streamline operations, reduce waste, and minimize process variability.
Develop and sustain a continuous improvement culture within manufacturing plants.
Improve operational efficiency through systematic process optimization, KPIs, and Industry 4.0 tools.
Design and execute an operational excellence roadmap aligned with organizational objectives.
Lead change and engage teams effectively to ensure long-term success in excellence initiatives.
Course Audience
This course is ideal for professionals responsible for driving productivity, quality, and continuous improvement in manufacturing, including:
Manufacturing and Operations Managers
Production Supervisors and Plant Managers
Quality Assurance and Continuous Improvement Specialists
Industrial and Process Engineers
Supply Chain and Logistics Professionals in Manufacturing
Any professional aiming to enhance efficiency, productivity, and sustainability in manufacturing operations
Course Methodology
This course uses a dynamic, participatory approach to maximize understanding and practical skill application. The instructor employs a variety of adult learning techniques, including:
Interactive lectures and discussions
Collaborative group activities
Real-world case studies and problem-solving exercises
Video presentations illustrating practical applications of OpEx principles
Participants will gain practical experience and actionable strategies that can be directly applied to their manufacturing environments.
Course Outline
Day One: Foundations of Manufacturing Operational Excellence
Evolution of operational excellence in manufacturing
Competitive drivers: cost, quality, flexibility, speed
Key concepts: Lean, Six Sigma, Kaizen, Continuous Improvement
OpEx framework: people, process, technology, culture
Case studies of global manufacturing leaders
Day Two: Lean Manufacturing and Process Optimization
Lean principles and waste elimination (8 wastes)
Value Stream Mapping (VSM) to identify bottlenecks
Standardized work and 5S workplace organization
Just-in-Time (JIT) and pull production systems
Workshop: Developing a Lean process improvement plan
Day Three: Quality, Reliability, and Continuous Improvement
Six Sigma methodology (DMAIC) for variation reduction
Root cause analysis tools: Pareto, Ishikawa/fishbone, FMEA
Total Productive Maintenance (TPM) for equipment reliability
Embedding Kaizen and continuous improvement cycles
Group activity: Problem-solving simulation using Six Sigma tools
Day Four: Performance Measurement and Data-Driven Excellence
Key Performance Indicators (KPIs) for manufacturing excellence
Overall Equipment Effectiveness (OEE): measurement and improvement
Linking performance metrics to strategic objectives
Leveraging data analytics and Industry 4.0 tools
Workshop: Building a performance dashboard and KPI alignment plan
Day Five: Leadership, Culture, and Sustaining Excellence
Leadership’s role in OpEx transformation
Managing change and overcoming resistance
Building a high-performance culture and employee engagement
Developing an Operational Excellence Roadmap
Capstone case study: Designing an end-to-end OpEx strategy for a manufacturing organization
Certificates
On successful completion of this training course, HighPoint Certificate will be awarded to the delegates. Continuing Professional Education credits (CPE): In accordance with the standards of the National Registry of CPE Sponsors, one CPE credit is granted per 50 minutes of attendance.