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Continuous Improvement Tools

Operational Excellence Training

Without an effective strategy for Continuous Improvement, your business runs the risk of stagnating and falling behind in today’s competitive marketplace. Every commercial organisation must consistently strive to improve its products, its services, and its internal processes in order to offer real value and the utmost in customer excellence at all times. Rather than addressing a single system or one specific methodology, continuous improvement revolves around the concept that there’s always a better way to accomplish something, whether it’s based on small, incremental improvements at the level of the individual, or larger, organisation-wide changes in procedure.

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Without an effective strategy for Continuous Improvement, your business runs the risk of stagnating and falling behind in today’s competitive marketplace. Every commercial organisation must consistently strive to improve its products, its services, and its internal processes in order to offer real value and the utmost in customer excellence at all times. Rather than addressing a single system or one specific methodology, continuous improvement revolves around the concept that there’s always a better way to accomplish something, whether it’s based on small, incremental improvements at the level of the individual, or larger, organisation-wide changes in procedure.

From workplace organisation and standard operating procedures, to process synchronisation and quality management, it’s important that the people involved in improving your company’s processes are given the right knowledge, tools, and techniques to successfully implement a systematic approach. In developing a team attitude toward improving quality at all levels, managers and business owners must demonstrate their own commitment by providing the necessary training and support. 

The methods, skills, and procedures taught in this course will allow you to direct and facilitate improvement in all areas of your business operations, boosting performance in total productive maintenance, changeover and set-up, and production levelling and scheduling through the adoption of practices like value stream mapping, and the principles of poka-yoke.

By completing this course, you’ll acquire all the valuable and practical skills your business needs to consistently achieve operational excellence and inspire customer delight. You’ll learn how to apply both basic and advanced continuous improvement tools to bump up efficiency, as you motivate your personal professional performance alongside that of your company’s various functions and departments. This course will also provide you with the up-to-date knowledge and analysis that will make it possible for your company to remain current in the marketplace, while meeting and exceeding customer needs faster and with greater accuracy than the competition.

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What's inside

Learning objectives

  • You’ll know how to add value, eliminate waste, and propel the efficiency of your business model forward with lean value stream mapping and analysis.
  • You’ll learn how to implement 6 s methodology to improve workplace morale, safety, and productivity inside a clean, organised, and high-performance environment.
  • You’ll understand how to create and execute standard operating procedures for developing reliable and repeatable processes
  • You’ll know how to employ total productive maintenance (tpm) to improve equipment availability, reliability, and overall effectiveness.
  • You’ll discover how to use poka-yoke methodology and devices to identify and prevent potential flaws in the pursuit of a zero-defect and error-free workplace.
  • You’ll have the ability to construct and apply a quick changeover and set-up time reduction program that’s both profitable and adaptable to product changeovers
  • You’ll learn how to vastly improve production planning, levelling, and scheduling in order to increase efficiency and ensure customer satisfaction.
  • You’ll be fully competent in the use of a complete set of continuous improvement tools dedicated to attaining superior results at all levels of your company
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Syllabus

Value Stream Mapping
Course Introduction

Download the presentation slides for this section

Total Productive Maintenance Basics - Terms, Definitions, Approaches
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The Purpose of Value Stream Mapping (VSM)
VSM Process - Stage 1 and Stage 2
VSM Process - Stage 3
VSM Process - Stage 4, Stage 5 and Stage 6
VSM Benefits,Types of Mapping,and Applications.Mapping Tips and Good Practices.
Section Summary
VSM Quiz
6 S Workplace Organization
The Traditional TPM Model
The Role of 6 S in Lean and Quality. Applications and Benefits.
The 6 S Process - Step 1 and Step 2
The 6 S Process - Steps 3 through 6
The 6 S Implementation Plan. Visual Factory.
Key Success Factors to 6 S Excellence
6 S Quiz
Standardized Work and Standard Operating Procedures
Levelling Techniques
Standard Operations Basics
Basic Elements and Forms of Standard Operations
Standard Operations and Operations Improvements
Sustaining Successful Standard Operations
Standardized Work Quiz
Total Productive Maintenance
Overall Equipment Effectiveness and Six Big Losses
TPM Implementation
Maintenance Performance Indicators
Requirements for Levelling Production Schedules
TPM Quiz
Poka Yoke and Mistake Proofing
Source Inspection and Poka Yoke
Poka Yoke Approaches and Principles
Poka Yoke Devices
Poka Yoke and Zero Defects Checklists
Level Scheduling in Pull Production
Poka Yoke Quiz
SMED, Quick Changeover and Setup Time Reduction
SMED Basics. Types of Changeover Operations.
Changeover Costs
Changeover Improvement Process - Steps 1 through 3
Changeover Improvement Process - Steps 4 through 6
Techniques for Setup Reduction
Improving Changeover Rules. Benefits.
SMED Quiz
Production Levelling and Scheduling
Adapting to Schedule Changes
Production Levelling and Scheduling Basics
Production Planning and Scheduling - MTS
Production Planning and Scheduling - ATO
Production Planning and Scheduling - MTO and Hybrid
The Eleven Scheduling Concepts
Production Levelling and Scheduling Quiz
Process Balancing and Synchronization
Total Quality - Principles, Practices and Techniques
Process Synchronization and Bottleneck Scheduling
Process Balancing - Part 1
Process Balancing - Part 2
The Theory of Constraints - Basics
Implementing the TOC
Process Balancing and Synchronization Quiz
Quality Management - Principles, Practices, Tools
Defining Quality
Quality Costs
Quality Cost Measurement
Quality Cost Reporting
Quality Costs and Decision Making
Seven Classic Quality Tools
Management and Planning Tools
Process Improvement Tools
Innovation and Creativity Tools
Lean Tools
Performance Excellence in Organizations
Quality Management Quiz
Course Closure

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Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Continuous Improvement Tools with these activities:
Review Basic Statistics Concepts
Reinforce your understanding of basic statistical concepts, which are foundational for understanding process variation and control charts used in continuous improvement.
Browse courses on Statistical Process Control
Show steps
  • Review descriptive statistics concepts.
  • Practice calculating mean, median, and standard deviation.
  • Familiarize yourself with different types of data distributions.
Read 'The Goal: A Process of Ongoing Improvement'
Understand the principles of the Theory of Constraints through a narrative that makes the concepts more relatable and memorable.
View The Goal: A Process of Ongoing Improvement -... on Amazon
Show steps
  • Read a few chapters each day.
  • Reflect on how the concepts apply to different business settings.
  • Discuss the book with peers.
Map a Value Stream for a Simple Process
Apply the value stream mapping techniques learned in the course to a real-world process to identify areas for improvement.
Show steps
  • Select a simple process to map.
  • Create a current state value stream map.
  • Identify areas for improvement and create a future state map.
  • Present your findings.
Four other activities
Expand to see all activities and additional details
Show all seven activities
Read 'Gemba Kaizen: A Commonsense, Low-Cost Approach to Management'
Gain practical insights into implementing Kaizen principles through real-world examples and case studies.
View Gemba Kaizen: A Commonsense, Low-Cost Approach... on Amazon
Show steps
  • Read a few chapters each day.
  • Identify Kaizen opportunities in your own workplace.
  • Share your insights with colleagues.
Develop a 6S Implementation Plan for Your Workspace
Apply the 6S methodology to improve the organization, cleanliness, and efficiency of your own workspace.
Show steps
  • Assess the current state of your workspace.
  • Develop a plan for each of the 6S steps.
  • Implement your plan and document the results.
Calculate Overall Equipment Effectiveness (OEE)
Practice calculating OEE using different scenarios to solidify your understanding of this key performance indicator.
Show steps
  • Find sample data sets for equipment performance.
  • Calculate availability, performance, and quality rates.
  • Calculate the overall OEE score.
  • Analyze the results and identify areas for improvement.
Design a Poka-Yoke Device for a Common Error
Apply the principles of Poka-Yoke to design a device that prevents a common error in a specific process.
Show steps
  • Identify a common error in a process.
  • Brainstorm potential Poka-Yoke solutions.
  • Design and prototype a Poka-Yoke device.
  • Test and refine your design.

Career center

Learners who complete Continuous Improvement Tools will develop knowledge and skills that may be useful to these careers:
Continuous Improvement Manager
A Continuous Improvement Manager leads initiatives to enhance processes and systems across an organization. This course helps a Continuous Improvement Manager direct and facilitate improvement in all areas of business operations, boosting performance in maintenance, changeover and setup, and production leveling and scheduling. The course offers the skills to implement continuous improvement tools to boost efficiency and motivate personal professional performance. Knowledge of both basic and advanced tools makes this applicant highly desirable in the role of Continuous Improvement Manager.
See salaries and explore the career path for Continuous Improvement Manager
Lean Manufacturing Engineer
A Lean Manufacturing Engineer applies lean principles to optimize manufacturing processes and eliminate waste. This course helps a Lean Manufacturing Engineer add value, eliminate waste, and propel the efficiency of a business model forward via the practice of lean value stream mapping and analysis This course provides the tools to streamline production, reduce changeover times, and improve overall equipment effectiveness. The course's coverage of 6 S methodology will help a Lean Manufacturing Engineer improve workplace organization, safety, and productivity.
See salaries and explore the career path for Lean Manufacturing Engineer
Process Improvement Specialist
A Process Improvement Specialist focuses on streamlining workflows and enhancing efficiency within an organization. This course dives into methodologies like value stream mapping, which is directly applicable to identifying bottlenecks and optimizing processes. The course's emphasis on continuous improvement tools and techniques helps a Process Improvement Specialist systematically analyze and refine operations. Learning about 6 S methodology will help a Process Improvement Specialist improve workplace organization, safety, and productivity.
See salaries and explore the career path for Process Improvement Specialist
Management Consultant
A Management Consultant advises organizations on improving their performance and efficiency. This course can help a Management Consultant direct and facilitate improvement in all areas of business operations, boosting performance in maintenance, changeover and setup, and production leveling and scheduling. This course also provides a Management Consultant with the up-to-date knowledge and analysis that will make it possible for their company to remain current in the marketplace, while meeting and exceeding customer needs faster and with greater accuracy than the competition.
See salaries and explore the career path for Management Consultant
Business Process Analyst
A Business Process Analyst evaluates and improves business processes to enhance efficiency and effectiveness. This course helps a Business Process Analyst implement 6 S methodology to improve workplace morale, safety, and productivity inside a clean, organized, and high-performance environment. The course's systematic approach to continuous improvement aligns directly with the responsibilities of a Business Process Analyst, enabling them to identify areas for enhancement and implement solutions. The knowledge of value stream mapping helps a Business Process Analyst identify wasteful steps.
See salaries and explore the career path for Business Process Analyst
Operations Manager
An Operations Manager oversees the daily activities of a company, ensuring efficient and effective operations. This course is a practical resource because it equips one with the skills to enhance efficiency, reduce waste, and boost overall performance. This course helps an Operations Manager implement total productive maintenance, quick changeover strategies, and production leveling techniques, all of which are essential for operational excellence. Knowledge of standardized work and standard operating procedures is crucial for the Operations Manager.
See salaries and explore the career path for Operations Manager
Industrial Engineer
An Industrial Engineer optimizes processes and systems to improve efficiency and productivity. This course provides the methods, skills, and procedures to allow one to direct and facilitate improvement in all areas of business operations. An Industrial Engineer might also have a masters degree in industrial engineering. This course helps an Industrial Engineer implement 6 S methodology to improve workplace morale, safety, and productivity inside a clean, organized, and high-performance environment.
See salaries and explore the career path for Industrial Engineer
Operations Analyst
An Operations Analyst analyzes operational data to identify areas for improvement and efficiency gains. This course helps an Operations Analyst implement 6 S methodology to improve workplace morale, safety, and productivity inside a clean, organized, and high-performance environment. This course may be useful because it enables one to add value, eliminate waste, and propel the efficiency of the business model forward with lean value stream mapping and analysis. The course's focus on data-driven decision-making helps drive effective strategies.
See salaries and explore the career path for Operations Analyst
Quality Assurance Manager
A Quality Assurance Manager is responsible for maintaining and improving the quality of products and services. This course helps a Quality Assurance Manager implement poka-yoke methodologies to prevent defects and ensure a zero-defect workplace. The quality management principles, practices, and tools covered in the course enable a Quality Assurance Manager to systematically monitor and enhance quality control processes. The course modules on quality costs and quality cost measurement inform a data-driven approach to quality management for the Quality Assurance Manager.
See salaries and explore the career path for Quality Assurance Manager
Reliability Engineer
A Reliability Engineer focuses on improving the reliability and maintainability of equipment and processes. A Reliability Engineer can use this course to learn how to employ total productive maintenance to improve equipment availability, reliability, and overall effectiveness. The Reliability Engineer will have the ability to construct and apply a quick changeover and set-up time reduction program that’s both profitable and adaptable to product changeovers. This course will help Reliability Engineers implement strategies for error-proofing and mistake prevention.
See salaries and explore the career path for Reliability Engineer
Process Technician
A Process Technician monitors and maintains production processes, identifying and resolving issues. This course may be useful to help a Process Technician create and execute standard operating procedures for developing reliable and repeatable processes. A Process Technician can use this course to help improve equipment availability, reliability, and overall effectiveness. This course might also help a Process Technician vastly improve production planning, leveling, and scheduling in order to increase efficiency and ensure customer satisfaction.
See salaries and explore the career path for Process Technician
Manufacturing Supervisor
A Manufacturing Supervisor oversees production processes and ensures efficiency and quality. This course will help a Manufacturing Supervisor improve equipment availability, reliability, and overall effectiveness. This course may be useful to adopt practices like value stream mapping, and the principles of poka-yoke. A Manufacturing Supervisor can use the skills from this course to direct and facilitate improvement in areas of business operations, boosting performance in changeover and set-up, and production leveling and scheduling.
See salaries and explore the career path for Manufacturing Supervisor
Production Supervisor
A Production Supervisor oversees the daily operations of a production line, ensuring smooth and efficient workflow. This course may be useful because it provides the tools to vastly improve production planning, leveling, and scheduling in order to increase efficiency and ensure customer satisfaction. This course's focus on quick changeover and setup time reduction helps a Production Supervisor minimize downtime and maximize output. The course's emphasis on standardized work and standard operating procedures helps to ensure consistent and reliable processes for the Production Supervisor.
See salaries and explore the career path for Production Supervisor
Project Manager
A Project Manager plans, executes, and closes projects, often with a focus on process improvement. This course may be useful because it enables one to construct and apply a quick changeover and setup time reduction program that’s both profitable and adaptable to product changeovers. The course's teachings on change management and process synchronization are particularly relevant for managing projects that involve significant process improvements. The principles taught in this course will allow a project manager to direct and facilitate improvement in all areas of business operations.
See salaries and explore the career path for Project Manager
Supply Chain Analyst
A Supply Chain Analyst analyzes and optimizes the flow of goods and information throughout the supply chain. This course may be useful because it promotes efficiency, reduces waste, and improves overall performance. The value stream mapping techniques taught in this course help a Supply Chain Analyst identify and eliminate bottlenecks in the supply chain. The course's modules on production leveling and scheduling will help a Supply Chain Analyst optimize inventory management and reduce lead times.
See salaries and explore the career path for Supply Chain Analyst

Reading list

We've selected two books that we think will supplement your learning. Use these to develop background knowledge, enrich your coursework, and gain a deeper understanding of the topics covered in Continuous Improvement Tools.
Cover image
The Goal
Save
Business novel that illustrates the principles of the Theory of Constraints (TOC) in a compelling and accessible way. It provides a practical understanding of identifying and eliminating bottlenecks in a production process. Reading this book will help you grasp the core concepts of process improvement and apply them to real-world scenarios. It is highly recommended as additional reading to complement the course material.
The Goal: A Process of Ongoing Improvement - 30th...
Paperback
$$
The Goal: Excellence In Manufacturing
Paperback
$$$$
(日本語) The Goal, Second Revised Edition
Tankobon Softcover
$$
The Goal: A Process of Ongoing Improvement
Paperback
$$$
The Goal: A Process of Ongoing Improvement
Kindle Edition
$$
Cover image
Gemba Kaizen: A Commonsense, Low-Cost Approach to...
Save
Provides a practical guide to implementing Kaizen principles in the workplace. It emphasizes the importance of going to the 'Gemba' (the actual place where work is done) to observe and understand processes. Reading this book will give you a deeper understanding of how to drive continuous improvement through small, incremental changes. It valuable resource for anyone involved in process improvement initiatives.
Gemba Kaizen: A Commonsense, Low-Cost Approach to...
Paperback
Check
Gemba Kaizen: A Commonsense, Low-Cost Approach to...
Kindle Edition
Check

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Effort
9.5 total hours
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Operational Excellence Training
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English
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