INTRODUCTION FOR IMPROVING MANUFACTURING EFFICIENCY
In today’s competitive manufacturing landscape, optimizing operational efficiency is crucial for achieving higher productivity, reducing costs, and improving product quality. This intensive 2-day program is designed to equip manufacturing professionals with practical tools, techniques, and strategies to identify inefficiencies, eliminate waste, and drive continuous improvement in their operations.
Participants will gain a solid understanding of key concepts such as Lean manufacturing, waste reduction, time study methods, and Overall Equipment Effectiveness (OEE). The course combines theoretical knowledge with hands-on activities, real-life case studies, and group exercises to ensure immediate applicability in the workplace.
By the end of the program, attendees will be able to:
- Analyze and map manufacturing processes to identify bottlenecks and waste
- Apply Lean principles and tools such as 5S, SMED, and visual management
- Measure and improve equipment and process performance using OEE
- Develop and implement standard work and continuous improvement plans
- Leverage digital technologies to enhance manufacturing efficiency
LEARNING OBJECTIVE
- Identify and eliminate the eight types of waste in manufacturing processes to enhance overall operational efficiency.
- Develop and analyze process maps, including Value Stream Maps, to pinpoint bottlenecks and non-value-added activities.
- Apply Lean tools such as 5S, SMED, and visual management to create more organized and efficient work environments.
- Calculate and interpret Overall Equipment Effectiveness (OEE) to measure and improve equipment performance.
- Design and implement standard work procedures and time study techniques to optimize cycle times and reduce variability.
- Develop continuous improvement plans leveraging problem-solving methods and digital technologies for sustained manufacturing productivity gains.
LEARNING OUTCOMES
- Participants will be able to recognize and classify the eight wastes within their manufacturing processes.
- Participants will demonstrate the ability to create and interpret process maps and Value Stream Maps to identify areas for improvement.
- Participants will implement Lean tools such as 5S and SMED to streamline workflows and reduce setup times.
- Participants will calculate Overall Equipment Effectiveness (OEE) and analyze its components to identify performance gaps.
- Participants will develop standardized work procedures based on time study data to enhance productivity and consistency.
- Participants will design actionable continuous improvement plans incorporating problem-solving techniques and digital tools to sustain efficiency improvements.
WHO SHOULD ATTEND
This course is ideal for production managers, industrial engineers, supervisors, and continuous improvement practitioners who want to accelerate operational excellence and create a culture of sustained efficiency gains.
- Production Managers
- Industrial Engineers
- Supervisors
- CI/Lean Teams
- Quality and Maintenance personnel
LEARNING METHODOLOGY
This program adopts an interactive, workshop-based learning approach designed to maximize participant engagement and practical application. Through a blend of hands-on activities, group discussions, real-life case studies, and simulation exercises, participants actively apply the concepts and tools learned to real manufacturing scenarios.
Key elements include:
- Experiential Learning: Participants engage in process mapping, waste identification, and time study exercises to gain firsthand experience.
- Collaborative Group Work: Team-based problem-solving and Kaizen project planning encourage peer learning and sharing of best practices.
- Visual and Practical Tools: Use of visual management aids, Lean simulations, and digital dashboards to reinforce learning concepts.
- Facilitated Discussions: Guided reflection and Q&A sessions help participants contextualize lessons to their own workplace challenges.
- Action Planning: Each participant develops a tailored efficiency improvement plan to implement post-workshop, ensuring knowledge transfer into practice.
This workshop format emphasizes active participation and real-world problem solving, enabling learners to build confidence and skills for driving efficiency improvements immediately
COURSE OUTLINE
Day 1: Foundations of Manufacturing Efficiency
Welcome & Introduction
- Course overview and learning objectives
- Icebreaker activity: “The Waste Hunt”
Understanding Efficiency in Manufacturing
- Definitions: Efficiency, Effectiveness, Productivity, OEE
- Key performance indicators (KPIs) for manufacturing
- Value-Added vs. Non-Value-Added activities
Lean Thinking and Waste Elimination
- Introduction to Lean principles
- The 8 Wastes (DOWNTIME) with real-world examples
- Gemba walk simulation and waste spotting activity
Process Mapping for Improvement
- SIPOC & Value Stream Mapping (VSM) basics
- Identifying bottlenecks and inefficiencies
- Group exercise: Mapping and analyzing a sample process
Time & Work Study Techniques
- Introduction to Work Measurement
- Time study vs. Predetermined Time Systems (e.g., MOST, MTM)
- Basics of cycle time analysis and standard work
Quick Changeover and SMED
- Impact of setup time on efficiency
- SMED methodology
- Activity: Identify SMED opportunities in your workplace
Day 2: Tools and Strategies for Efficiency Gains
Overall Equipment Effectiveness (OEE)
- Understanding the 3 components: Availability, Performance, Quality
- Calculating OEE with examples
- Root causes of OEE losses and countermeasures
Visual Management & Standard Work
- Benefits of workplace visualization
- 5S as a foundation for efficient workspaces
- Developing and auditing standard work
Digital Tools for Manufacturing Efficiency
- Overview of IR4.0 enablers: IoT, MES, Real-Time Monitoring
- Using dashboards for productivity tracking
- Case study: Digital Lean transformation
Continuous Improvement & Kaizen Culture
- Engaging teams in improvement
- Daily management and problem-solving routines (PDCA, A3)
- Examples of Kaizen projects and ROI
Group Exercise: Efficiency Improvement Plan
- Teams select a process and develop an improvement roadmap
- Present findings and recommendations
Wrap-Up & Evaluation
- Key takeaways
- Q&A and feedback
