INTRODUCTION FOR MANUFACTURING PROCESS IMPROVEMENT
In today’s competitive industrial landscape, efficiency, quality, and agility are no longer optional—they’re essential. This 2-day workshop on Manufacturing Process Improvement is designed to empower professionals with the tools and techniques needed to analyze, improve, and sustain high-performing manufacturing operations.
Blending Lean principles, Six Sigma tools, and real-world case studies, this course offers a hands-on, practical learning experience. Whether you’re aiming to reduce waste, boost productivity, or eliminate process inefficiencies, this workshop will equip you with the skills to drive measurable improvement in your workplace.
LEARNING OBJECTIVES
- Understand Core Principles of Process Improvement
- Equip participants with foundational knowledge of Lean, Six Sigma, and continuous improvement methodologies used in modern manufacturing.
- Identify and Eliminate Waste in Manufacturing Processes
- Teach participants how to recognize inefficiencies and non-value-adding activities using tools like the 7 Wastes, Value Stream Mapping, and 5S.
- Analyze and Solve Process Problems Using Data
- Develop participants’ ability to use data-driven tools such as Root Cause Analysis, KPIs, and the DMAIC framework to identify and resolve process issues.
- Apply Practical Tools for Real-World Improvements
- Enable hands-on experience with Lean and Six Sigma tools (e.g., SMED, Poka-Yoke, Visual Management) to drive measurable improvements on the shop floor.
- Foster a Culture of Continuous Improvement
- Encourage participants to lead change initiatives, support team collaboration, and implement sustainable process improvements in their organizations.
LEARNING OUTCOMES
- Explain Key Concepts of Lean and Six Sigma
- Participants will be able to describe the principles of Lean manufacturing and Six Sigma, including the DMAIC cycle and waste elimination.
- Map and Analyze Manufacturing Processes
- Participants will be capable of creating detailed process maps, identifying bottlenecks, and analyzing workflows for improvement opportunities.
- Use Problem-Solving Tools to Address Root Causes
- Participants will apply tools like 5 Whys, Fishbone Diagrams, and Pareto Charts to systematically identify and address process issues.
- Implement Practical Improvement Techniques
- Participants will demonstrate how to apply methods such as 5S, SMED, Standard Work, and Poka-Yoke to real or simulated scenarios in manufacturing.
- Develop and Present a Process Improvement Plan
- Participants will be able to design, document, and communicate a simple improvement plan for a selected process, showcasing measurable benefits.
LEARNING METHODOLOGY: WORKSHOP-BASED APPROACH
This course adopts a hands-on, interactive workshop format to ensure participants gain practical skills and real-world problem-solving experience. The methodology is designed to balance conceptual learning with application-oriented exercises for maximum engagement and retention.
Key Features of the Workshop Methodology
- Experiential Learning
- Participants learn by doing through real-world case studies, simulations, and group activities.
- Emphasis on applying Lean and Six Sigma tools in practical, manufacturing-focused scenarios.
- Interactive Group Work
- Team-based exercises encourage collaboration, peer learning, and diverse perspectives.
- Group projects foster teamwork and communication skills while solving process challenges.
- Process Walks & Observation Tasks
- Participants are encouraged to observe actual or simulated production processes to identify improvement opportunities.
- Facilitator-Led Discussions
- Experienced trainers guide discussions to connect theory to industry practices.
- Sessions include open Q&A, real-time feedback, and knowledge sharing.
- Problem-Solving Workshops
- Hands-on sessions focus on using tools such as Value Stream Mapping, Root Cause Analysis, and DMAIC to solve problems collaboratively.
- Reflection & Action Planning
- Participants develop a personal or team-based action plan for implementing improvements in their own workplace.
TARGET AUDIENCE
Production supervisors, quality engineers, process improvement specialists, plant managers, and industrial engineers.
COURSE CONTENT
Foundations of Process Improvement
- Session 1: Introduction to Process Improvement
- Importance of process improvement in manufacturing
- Common manufacturing challenges
- Key goals: Efficiency, Cost Reduction, Quality
- Session 2: Lean Manufacturing Principles
- 8 Wastes (Muda)
- 5S System
- Kaizen (Continuous Improvement)
- Value Stream Mapping (VSM)
- Session 3: Process Mapping and Analysis
- Types of process maps (flowchart, SIPOC)
- Identifying bottlenecks and inefficiencies
- Hands-on activity: Process mapping workshop
- Session 4: Root Cause Analysis Techniques
- 5 Whys
- Fishbone (Ishikawa) Diagram
- Pareto Analysis
- Case Study: Identifying root causes in a sample scenario
- Session 5: Metrics & Data in Manufacturing
- Key Performance Indicators (KPIs)
- OEE (Overall Equipment Effectiveness)
- Data collection methods on the shop floor
Tools, Implementation & Workshop / Case Studies
- Session 6: Six Sigma Basics & DMAIC Methodology
- What is Six Sigma?
- Overview of DMAIC: Define, Measure, Analyze, Improve, Control
- Hands-on: Define & Measure phases with real examples
- Session 7: Improvement Tools & Techniques
- SMED (Single-Minute Exchange of Dies)
- Poka-Yoke (Error Proofing)
- Standard Work
- Visual Management
- Session 8: Implementing Process Improvements
- Change management basics
- Gemba walks
- Pilot testing vs full-scale rollout
- Building improvement teams
- Session 9: Case Studies & Group Activity
- Real-world examples of successful process improvements
- Group activity: Solve a manufacturing problem using DMAIC and Lean tools
- Presentation of group solutions
- Session 10: Roadmap to Continuous Improvement
- Building a culture of continuous improvement
- Long-term sustainability tips
- Resources & tools for ongoing learning
