Course Details

Objective

By the end of this course, participants will be able to:

• Understand the key principles of process management and optimization.
• Learn how to analyze and identify inefficiencies and bottlenecks in industrial processes.
• Gain practical knowledge on process optimization techniques such as Lean, Six Sigma, and process control.
• Develop skills for improving process quality, reducing waste, and increasing productivity.
• Implement strategies for optimizing energy usage, reducing operational costs, and increasing profitability.
• Understand the role of data analysis and process monitoring in continuous improvement efforts.

Content

Day 1: Introduction to Process Management and Optimization

• Overview of process management and optimization concepts.
• The role of process management in improving operational efficiency and reducing costs.
• Key performance indicators (KPIs) for process performance and optimization.
• Types of industrial processes: Batch vs. continuous processes, and service processes.
• The principles of process flow and system thinking.

Day 2: Process Analysis and Identification of Inefficiencies

• Analyzing process flow: Mapping and modeling techniques (e.g., flowcharts, SIPOC diagrams).
• Identifying process bottlenecks, delays, and inefficiencies.
• Root cause analysis techniques: Fishbone diagrams, 5 Whys, Pareto analysis.
• Process variability: Understanding and managing variability in production.
• Process performance metrics: Cycle time, throughput, yield, and defect rates.

Day 3: Process Optimization Techniques

• Introduction to Lean principles: Value stream mapping, waste reduction (Muda), and 5S methodology.
• Six Sigma methodologies: DMAIC (Define, Measure, Analyze, Improve, Control).
• Process control and monitoring tools: Statistical process control (SPC), control charts, and process capability analysis.
• The role of automation and digitalization in process optimization.
• Best practices in process re-engineering for enhanced efficiency.

Day 4: Energy and Resource Optimization

• Strategies for reducing energy consumption in industrial processes.
• Resource optimization: Water, raw materials, and human resources.
• Techniques for minimizing waste and reducing environmental impact.
• The role of energy audits and energy management systems (EnMS).
• Implementing energy-efficient technologies and green manufacturing practices.

Day 5: Continuous Improvement and Performance Monitoring

• Developing a continuous improvement culture in process management.
• Implementing a Kaizen approach: Small, incremental improvements over time.
• The role of data analysis and process monitoring in continuous improvement.
• Advanced process optimization tools: Simulation modeling, optimization algorithms, and data analytics.
• Reviewing and measuring process improvements: Post-implementation audits and adjustments.

NOTE:

Pre-& Post Tests will be conducted.

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

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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