Continuous improvement is a fundamental pillar of operational success in the manufacturing industry, but it remains a significant challenge for productivity professionals. To remain competitive and efficient, manufacturing organizations must consistently monitor, identify, and resolve productivity issues that arise within their systems. This program is designed to equip participants with the tools, techniques, and methodologies to tackle these challenges head-on, ensuring that key productivity standards are maintained and continuously improved.
Through this comprehensive one-day training, participants will be introduced to the advanced practical PDCA methodology, a powerful approach for managing and resolving problems while fostering ongoing improvement. PDCA is a proven framework that allows teams to methodically plan solutions, implement corrective actions, evaluate outcomes, and adapt processes for sustained growth.
A core component of the program is learning how to conduct structured Gemba walks, an essential practice for identifying and addressing inefficiencies on the shop floor. Participants will be guided on how to observe and interact with processes in real-time, using specific techniques to uncover hidden bottlenecks, failures in critical productivity standards, and other operational deviations. This hands-on approach allows professionals to gain insights directly from the workspace, helping them spot issues that may not be visible through traditional data analysis alone.
During the Gemba walk, participants will also learn how to apply the Catchball Game to troubleshoot deviations that can be easily detected through basic visual management, direct observation, or employee engagement. These issues might include defective products, delays in production, or underperforming machines—all of which can impact overall productivity if left unaddressed.
The program places a strong emphasis on root cause analysis—a critical skill for uncovering the underlying reasons behind process failures and deviations. Participants will explore proven techniques such as the catchable game, 5 Whys and affinity diagrams to systematically analyze issues and ensure that corrective actions are targeted at the real causes, not just symptoms. By tackling the root cause, participants will be better equipped to implement effective, long-lasting solutions that improve both efficiency and quality.
Through interactive case studies and hands-on exercises, participants will apply the techniques they’ve learned in real-world scenarios. This will deepen their understanding of corrective action planning, problem-solving methods, and continuous improvement strategies, providing them with the confidence to lead improvement initiatives in their own organizations. By the end of the program, participants will not only understand how to resolve specific issues, but also how to create a culture of continuous improvement within their teams and organizations. Armed with practical skills and strategies, they will be empowered to drive operational excellence, ensuring that productivity standards are continuously met, and operational challenges are addressed with agility and foresight.
This program is ideal for productivity professionals, team leaders, and anyone involved in the day-to-day operations of a manufacturing facility looking to enhance their problem-solving capabilities and drive continuous operational improvements.
Target Audience
The target audience includes anyone responsible for achieving and maintaining key productivity standards, as well as those involved in driving and managing improvement projects.
