Course Details

Objective

By the end of the course, participants will be able to understand

• Understand Lean principles and how they align with quality control practices in oil and gas.
• Learn to identify and eliminate waste that hinders quality and efficiency.
• Gain hands-on experience with tools like Value Stream Mapping, Root Cause Analysis, and Kaizen.
• Explore case studies and real-world examples tailored to upstream, midstream, and downstream operations.
• Develop actionable plans to implement Lean strategies in your organization.

Content

Day 1: Introduction to Lean and Quality Control in Oil and Gas

• Foundations of Lean Principles
  • Introduction to Lean thinking and its relevance to the oil and gas industry.
  • Overview of key Lean tools (5S, Value Stream Mapping, Kaizen).
  • Understanding waste (Muda, Mura, Muri) and its impact on quality.
• Quality Control Fundamentals
  • Key quality control challenges in oil and gas.
  • Integrating Lean methodologies with quality management systems (e.g., ISO 9001).
  • Case studies of Lean-driven quality improvements.
• Workshop: Identifying waste in your current quality processes.

Day 2: Lean Tools and Techniques for Quality Control

•  Value Stream Mapping and Process Improvement
  • Mapping the current state of quality control processes.
  • Identifying bottlenecks, redundancies, and value-added activities.
•  Root Cause Analysis and Problem Solving
  • Tools: Fishbone diagram, 5 Whys, and Failure Modes and Effects Analysis (FMEA).
  • Strategies for eliminating root causes of quality defects.
• Workshop: Create a value stream map for a quality control process in your organization.

Day 3: Lean Implementation in Quality Control

• Standard Work and Visual Management
  • Importance of standardizing quality control processes.
  • Designing visual cues to enhance process adherence and efficiency.
• Continuous Improvement and Kaizen Events
  • How to run Kaizen events for quality improvement in oil and gas operations.
  • Building a culture of continuous improvement.
• Workshop: Develop a standardized work process for a key quality control activity.

Day 4: Lean in Oil and Gas Quality Control Applications

• Applying Lean to Upstream, Midstream, and Downstream Operations
  • Tailoring Lean tools for exploration, production, refining, and distribution.
  • Examples of quality control applications across the value chain.
• Digital Tools and Data-Driven Quality Management
  • Leveraging IoT, data analytics, and AI for quality improvement.
  • Real-time monitoring and predictive analytics in quality control.
• Workshop: Identify digital tools that could enhance your organization’s quality control.

Day 5: Sustainability, Integration, and Action Planning

• Sustaining Lean Quality Control Excellence
  • Embedding Lean practices into the organizational culture.
  • Metrics and KPIs for long-term success.
• Developing an Action Plan
  • Aligning Lean quality initiatives with business goals.
  • Creating a step-by-step action plan for implementing Lean quality improvements.
• Workshop: Develop an actionable Lean quality improvement plan for your organization.
• Closing: feedback session.

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions