Introduction:

This training program is designed to equip participants with essential skills in safety, operational reliability, quality control, costing systems, and people management. It empowers them to apply advanced strategies and methodologies, fostering a culture of continuous improvement and sustainable organizational success.

Program Objectives:

At the end of this program, participants will be able to:

Understand the best practice techniques for achieving operational excellence.
Understand a range of technical and human risks and their implications to the operational organization.
Design a tailored operational improvement plan for their organization that tackles the major risk areas.
Learn a practical approach to developing an action plan to utilize these technologies in their areas of responsibility, fitting them into the overall operations strategy, and measuring benefits.

Targeted Audience:

Operations Professionals.
Process Professionals.
Reliability & Maintenance Professionals.
Safety Professionals.
Professionals involved in process improvement.

Program Outlines:

Unit 1:

Safety:

Behavioral safety.
Risk Assessment.
Permits to Work, Hazard & Operability Studies and other common systems.
Analyzing Near Misses, Incidents & Accidents.
Complete Safety Management System.

Unit 2:

Continuity of Operations – Plant Reliability:

Operational Risks.
Vulnerability & Resilience Assessment.
Reliability Improvement.
Plant Asset Care.
Developing the Right Maintenance Strategy.
Agile Manufacturing.

Unit 3:

Quality:

Process Control.
Six Sigma: minimizing the six losses and seven wastes.
Continuous Improvement Model.
Quality Assurance.
Standard Operating Procedures.
Error Proofing Techniques.

Unit 4:

Costing:

Costing systems.
Lean manufacturing.
Inventory control systems.
Life cycle approach to equipment selection.
Asset management.
Benchmarking.

Unit 5:

People Management / Development:

Leadership.
Empowerment & Engagement.
Change Management.
Performance Management Systems.
Skills & Competency Development.
Problem Solving.

Building Operational Excellence in the Process Industry