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Empowering sustainable change
List of Training Programs
::: Lean Thinking for Transformational Leadership                 2
​
::: Kaizen​​                                                      3
::: 5S & Visual Management                                        4
::: Value Stream Mapping                                          5
::: Training Within Industry (TWI)                                6
::: PDCA Problem Solving                                          7
::: A3 Problem Solving                                            8
::: Total Productive Maintenance (TPM)​​                          9
::: Total Quality Management (TQM)                                10
​::: Hoshin Kanri                                                 11
::: Cost of Quality​                                              12
::: Benchmarking                                                  13
::: ​Suggestion System (Kaizen Teian) ​                           14
::: Six Sigma Overview                                            15
::: Lean Six Sigma Overview                                       16
​::: Delivering Service Excellence                                17
About Operational Excellence Consulting




                                                                                            1
                       Operational Excellence Consulting :: Empowering sustainable change
Lean Thinking for Transformational Leadership
Description                                                            Methodology
​                                                                      
Lean (a.k.a. TPS – Toyota Production System) is an organization-       Short lectures, individual exercises, group activities and discussions
wide continuous improvement initiative that is gaining popularity in   and Q&A​
the manufacturing, process and service industries today.
                                                                       Learning Objectives
This one-day workshop introduces you to the principles and key         
concepts of Lean. You will gain an understanding of productivity       •   Explain how Lean improves business performance
loss from the three major sources of waste:                            •   Describe the Lean principles and approach to continuous
                                                                           improvement
(1) Non-value added work,                                              •   Define value and waste
(2) Process variability and                                            •   Understand the applications of the Lean principles and Lean
(3) Process/System inflexibility (bottlenecks)                             "tools"
                                                                       •   Define the role of the Lean Leader
In addition, you will learn how Lean principles and tools can be       •   Define the critical success factors in starting and sustaining a
applied to eliminate non-value added work, create stable processes         Lean culture
and mistake-proof operations so as to significantly improve
productivity and increase value to customers.                          Program Outline
                                                                       
As a senior executive, you will gain a deeper insight into your role   •   Introduction to Lean
as a Lean Leader and create the right conditions to start and          •   Productivity Loss is Caused by Three Major Sources of Waste
sustain a successful Lean program.                                     •    Examples of Lean Adoption in Manufacturing and Service
​                                                                           Environments
Recommended Audience                                                   •    Lean Principles and Approach to Creating Customer Value
                                                                      •     Lean and Six Sigma
Senior executives, managers, project champions or project              •      Understanding Value and Waste
sponsors of manufacturing and service industries who are               •       Key Lean “Tools”
interested in getting a “big picture” perspective of Lean before       •        The Lean Framework 
embarking on the detailed planning and implementation                  •        Role of the Lean Leader
                                                                       •        Key Considerations in Developing a Lean Infrastructure
Duration: 1 day                                                        •         Developing "Kaizen Eyes"
                                                                       •         Sustaining a Lean Culture




                                                                                                                              2
                       Operational Excellence Consulting :: Empowering sustainable change
Kaizen
Description                                                             Methodology

Kaizen strategy is the single most important concept in Japanese        Short lectures, individual exercises, group activities and discussions
management – the key to successful Japanese companies such as           and Q&A
Toyota.
                                                                        Learning Objectives
Based on Masaaki Imai's teachings on 'Kaizen' and 'Gemba Kaizen',       ​
this workshop is specially designed for managers and supervisors        •   Explain the key concepts of Kaizen
who are interested in developing a Kaizen culture in the workplace      •   Manage Kaizen activities as a means to eliminate waste and
and facilitating Kaizen events as a mechanism to improve operational         provide increased value to customers
efficiency.                                                             •    Learn the key tools and techniques in the Kaizen approach to
                                                                              problem solving
Participants will learn the key concepts and benefits of Kaizen and     •     D efine the key steps in conducting a Kaizen event
how to manage Kaizen in their work areas to improve productivity        •      Explain the role of management in managing Kaizen activities
and customer value. This workshop will enable participants to
                                                                        •       ​Understand the critical success factors in sustaining Kaizen
understand the key tools and techniques for running Kaizen activities
                                                                                 activities
on a daily basis, problem solving, conducting a Kaizen event as well
as overcoming barriers to successful implementation.
                                                                        Program Outline
                                                                        
Recommended Audience
                                                                        •   Introduction to Kaizen
​
Managers, supervisors, facilitators and Continuous Improvement          •   Kaizen & Waste
steering committee members responsible for deploying Kaizen in the      •   Key Concepts of Kaizen
work areas                                                              •   Kaizen Management
                                                                        •   Kaizen Practices
Duration                                                                •   Kaizen Implementation
                                                                       •   Problem Solving
1-day and 2-day programs are available                                  •   Developing “Kaizen Eyes”
                                                                        •   Role of Management
                                                                        •   Critical Success Factors
                                                                        ​




                                                                                                                                                 3
                                      Operational Excellence Consulting :: Empowering sustainable change
5S & Visual Management
Description                                                              Learning Objectives
                                                                         ​
5S good housekeeping and workplace organization is a set of basic        •   Understand the importance and benefits of 5S
management principles that are widely adopted in industries              •   Define each of the 5S principles, and identify types of visual
today. As a foundation of Lean management, the key targets of 5S              management
are improved workplace efficiency, morale and safety.                    •    Explain how to implement each of the 5S principles
                                                                         •     Explain how to apply 5S in the office
In this workshop, you will learn how to mobilize and align your
management team to launch or improve a 5S and Visual                     •      Identify the infrastructure necessary for starting and sustaining
Management implementation in your organization. The workshop                     a 5S initiative in your organization
covers 5S and Visual Management best practices, step-by-step             •       Define the critical success factors for 5S implementation
implementation guidance, and the best ways to integrate 5S into
the organization’s culture to achieve sustainable world-class            Program Outline​
excellence. It includes the principles of 5S and Visual Management
and the benefits, initial implementation, future refinement, self-       •   Introduction & Overview of 5S
assessment as well as the infrastructure necessary to start and          •   What is 5S?
sustain a 5S initiative for your organization.                           •    Why 5S?
                                                                         •     5S as a Foundation of Lean Management
Recommended Audience
                                                                         •      5S Principles
                                                                                          - 1S: Sort (Seiri)
Managers, supervisors and 5S steering committee members
                                                                                          - 2S: Set In Order (Seiton)​
Methodology                                                                               - 3S: Shine (Seiso)
                                                                                         - 4S: Standardize (Seiketsu)
Short lectures, individual exercises, group activities and discussions                    - 5S: Sustain (Shitsuke)
and Q&A                                                                  •       Visual Management
​                                                                        •       5S Applications in Safety, Quality, Reliability & Waste
​Duration                                                                •       5S in the Office
                                                                        •        Starting, Launching & Promoting a 5S Initiative
1 day                                                                    •         Supporting Lean Tools for 5S Implementation
                                                                         •         Critical Success Factors
                                                                         




                                                                                                                                 4
                       Operational Excellence Consulting :: Empowering sustainable change
Value Stream Mapping
This workshop provides a step-by-step instruction to enable            ​Methodology
participants to create current state and future state value stream
maps, and to identify opportunities to achieve the future state that   Short lectures, individual exercises, group activities and discussions
have the greatest impacts on the business as well as customer          and Q&A
value.​ You will learn how the critical tool of value stream mapping
and analysis helps your organization see waste and opportunities,      Program Outline
and envision a Lean future state.
                                                                       •   Key Principles of Lean
Recommended Audience                                                   •   Understanding Value, Wastes & Inflexibility
​                                                                      •   Overview of Lean Methodology & Tools
Managers, supervisors, Lean practitioners and staff
                                                                       •   Introduction to Value Stream Mapping, Tools and Symbols
Learning Objectives                                                    •   Identifying a Business Value Stream
                                                                       •   Step-by-Step Approach to Value Stream Mapping
​Upon completion of this workshop, participants will be able to:       •   Assessing Value-Added and Non-Value-Added Activities
                                                                       •   Defining Goals and Gaps
•   Map a current-state value stream
                                                                       •   Definition of the Future State Value Stream
•   Develop a data collection plan for the value stream map
                                                                       •   Using Value Stream Map to Identify Lean Improvement Projects
•   Conduct end-to-end assessment of value-added versus non-
                                                                       •   Prioritizing & Selecting Lean Projects
    value-added activities
                                                                       •   Define Actions to Close Gap
•   Scope opportunities by framing project problem statements
    based on identified waste                                          
                                                                       Duration
•   Prioritize project based on strategic objectives
•   Develop action plan to achieve the future state                    2 days
•   Envision the Lean future state and create the future-state value
    stream map
•   Engage other teams in mapping their processes and surfacing
    more opportunities for improvement




                                                                                                                                                5
                                      Operational Excellence Consulting :: Empowering sustainable change
Training Within Industry (TWI)
Training Within Industry (TWI) is an integral part of Lean to          Recommended Audience
reinforce the practice of Standard Work. Standardized work
                                                                       Supervisors, Line Leaders, Charge-hands, Trainers and Assistant
eliminates waste, improves process stability and provides a baseline
                                                                       Foremen from manufacturing companies
for process improvement.
                                                                       Methodology
Program Objectives
                                                                       Short lectures, discussions and practice demonstrations
Job Relations (JR): To lead people by effectively and positively
dealing with relationship problems between the supervisor and the
                                                                       Program Outline
employee, and preventing these problems from developing in the
first place by maintaining positive employee relationships.            •   Overview and Introduction
                                                                       •   Role of Supervisors in Lean Manufacturing
Job Instruction (JI): To provide proper training and assuring this     •   Five Needs of Good Supervisors
training is effective in helping people do their jobs correctly and    •   Job Instruction (JI)
efficiently.                                                                     Four Steps for Job Instruction
                                                                                 Four Steps to Get Ready
Job Methods (JM): To improve processes and the workplace by
                                                                                 Job Breakdown – Important Steps, Key Points & Reasons
developing improvement proposals and implementing them to get
                                                                                 Training Timetables
improved results.
                                                                                 Special Instruction Problems (and how to handle them)
                                                                                 Job Instruction & Standard Work
Benefits
                                                                       •   Job Methods (JM)
•   Get more done with less machines and manpower                                Four Steps for Job Methods Improvement
•   Improve quality, reduce scrap by achieving standard work                     Job Breakdown Sheet
    across workers and shifts                                                    5W’s & 1H
•   Reduce safety incidents                                                      Eliminate, Combine, Rearrange & Simplify
•   Decrease training time, especially for temporary workers                     Job Method Improvement Proposal Sheet
•   Reduce labor hours                                                           Resistance & Resentment
•   Reduce grievances                                                  •   Job Relations (JR)
•   Transfer knowledge from a skilled workforce to an unskilled or               Chart on Supervisory Responsibility
    green workforce                                                              Foundations for Good Relations
                                                                                 Chart on the Individual
Duration: 2 days                                                                 How Problems Arise
                                                                                 Four Steps for Job Relations
                                                                       •   Sustaining TWI




                                                                                                                         6
                       Operational Excellence Consulting :: Empowering sustainable change
PDCA Problem Solving
Description                                                               Methodology

How do you solve business problems that are cross-functional and          Short lectures, individual exercises, group activities and discussions
there is not a single subject matter expert who has sufficient            and Q&A
knowledge about the real causes of the problem? How do you break
through the functional silos to obtain a detailed understanding of
the current processes and then develop a future state process that        Learning Objectives
involves all departments and gives you the true nature of the
problem to be solved?                                                     •   Understand the principles and key concepts of problem solving
                                                                         •   Learn how to apply the PDCA approach and basic quality tools to
In this workshop, you will learn the structured Plan-Do-Check-Act         •   problem solving
(PDCA) approach to problem solving. The PDCA problem solving
                                                                          •   Learn how to prepare an A3 problem solving report
process is a technique that is used by Toyota to identify problems,
analyze root causes and generate solutions. When combined with            •   Understand the roles of problem solving team
the basic quality ("QC") tools, real causes to business problems can      •   Define the critical success factors for effective problem solving
be identified and effective solutions can be put in place to prevent
similar problems from recurring in the future.
                                                                          Program Outline

Recommended Audience                                                      •   Introduction to Problem Solving
​                                                                         •   Concept of Problem Solving Teams
Any manager or staff who is interested in facilitating, leading or
                                                                          •   Overview of Process Management
participating in a problem solving project
                                                                          •   PDCA Approach to Problem Solving
                                                                          •   Problem Solving Tools
Duration                                                                  •   Examples & Practice Tips
                                                                         •   Project Reporting Using A3 Storyboard
2 Days                                                                    •   10 Common Mistakes​
                                                                          •   Critical Success Factors
                                                                          




                                                                                                                                                   7
                                        Operational Excellence Consulting :: Empowering sustainable change
A3 Problem Solving
Description                                                              Learning Objectives
​                                                                        
In this workshop, participants will learn the structured problem-        •   Identify the types of wastes that contribute to workplace
solving approach that uses a tool called the A3 Problem-Solving              inefficiency
Report. The A3 report is a tool that Toyota uses to propose              •   D efine the benefits of the A3 report
solutions to problems, give status reports on ongoing projects, and      •    Carry out the A3 problem solving process
report results of information gathering activity. The term "A3" is       •     Perform root cause analysis
derived from the paper size used for the report, which is the metric     •      Make a clear and concise A3 report
equivalent to the 11" x 17" paper.                                       ​
​                                                                        Program Outline
You will learn the steps to proceed from problem identification to
resolution in a fashion that fosters learning, collaboration, and        •   Introduction to Lean
personal development. The problem-solving team records the               •   Overview of the Types of Waste
results of investigation and planning in a concise, two-page             •    What is the A3 Report
document (the A3 Report) that facilitates knowledge sharing and          •     Why use the A3 Report
collaboration.                                                           •      The A3 Problem Solving Process - Step-by-step
                                                                                       - Identify a problem or need
Recommended Audience                                                                   - Conduct research to understand the current situation
​                                                                                      - Conduct root cause analysis
Lean managers, operations/production managers, engineers and                           - Devise countermeasures to address root causes
practitioners                                                                          - Develop a target state
                                                                                       - Create an implementation plan
Methodology                                                                            - Develop a follow-up plan with predicted outcomes
                                                                                       - Discuss plans with all affected parties
Short lectures, individual exercises, group activities and discussions                 - Obtain approval for implementation
and Q&A                                                                                - Implement plans
                                                                                       - Evaluate the results
Duration                                                                 •       Common Mistakes to Avoid
                                                                         •       Critical Success Factors
2 Days                                                                   •        Workshop: Making Your A3 Report
                                                                         •         ​Conclusion and Wrap-up
                                                                         




                                                                                                                                   8
                       Operational Excellence Consulting :: Empowering sustainable change
Total Productive Maintenance (TPM)
Description                                                             Methodology
​                                                                       
Total Productive Maintenance (TPM), is a company-wide initiative        Short lectures, individual exercises, group activities and discussions
for maximizing the effectiveness of equipment. The goal of the          and Q&A​
TPM program is to significantly increase labor and capital
productivity while, at the same time, increasing employee morale        Program Outline
and job satisfaction. TPM brings maintenance into focus as a            
necessary and vitally important part of the business. Targeted at all   •   Overview of TPM
levels of the organization, TPM and its 8 pillars provide the           •   TPM Foundations – 5S & Visual Management
necessary process and tools to achieve zero defects, zero
                                                                        •    TPM Tools
breakdowns and zero accidents.
                                                                        •     Equipment Loss & Overall Equipment Effectiveness (OEE)
Recommended Audience                                                    •     The 8 Pillars of TPM
​                                                                                 - Autonomous Maintenance
Managers, engineers, supervisors, TPM steering committee and                      - Planned Maintenance
other operational staff from production, engineering and                          - Early Equipment Management
maintenance                                                                       - Focused Improvement
                                                                                  - Quality Maintenance
Learning Objectives                                                               - Education and Training
                                                                                 - TPM in the Office
•   Understand the concept and management philosophy of TPM                       - Safety & Environmental Management
    as a foundation for Lean Transformation
                                                                        •      Improving Equipment Reliability through Integration of
•   Learn the 8 pillars of TPM activities, TPM implementation                 Autonomous Maintenance & Planned Maintenance
     strategy, roadmap and step-by-step approach                        •      TPM Roles and Responsibilities
•   Learn the TPM tools and be able to identify and eliminate loss     •       TPM Planning & Implementation
     through TPM implementation
                                                                        •        Critical Success Factors for TPM Implementation
•   Understand the Autonomous Maintenance process and how to
     improve equipment reliability                                      Duration
•   Understand the roles of a TPM implementation organization
     and the critical success factors                                   1-day and 2-day programs are available




                                                                                                                                                 9
                                      Operational Excellence Consulting :: Empowering sustainable change
Total Quality Management (TQM)
Description                                                           Methodology

This workshop is designed to help you, as a key manager,              Short lectures, individual exercises, group activities and discussions
understand how to approach quality as a company-wide                  and Q&A
effort. You will learn how to make a commitment, plan and begin
to implement systems for managing quality that integrates all the     Learning Objectives
people, processes and continuous improvement initiatives
together.                                                             •   Explain the Principles of Quality
                                                                      •   Describe the TQM framework (“House of Quality”)
Based on Philip Crosby's methodology, this workshop introduces        •   D efine the Four Key Activities for managing quality
participants to the Five Quality Principles and the Four Key          •    Explain the need for a culture change, starting at the top
Activities for Quality Management.                                    •    D emonstrate a personal commitment to total quality
                                                                      •     Explain the TQM implementation infrastructure
Finally, the role of the manager will be examined so as to identify
                                                                      •      D escribe how to put the systems for TQM into motion
what you, personally, can do to plan the improvement process and
communicate the need to change.                                       •       Identify ways to sustain TQM activities
                                                                      •        Understand a manager’s role in quality improvement
To manage and improve quality, a long-term commitment of time
and effort will be required. For these efforts to succeed, every      Program Outline
employee in the company must get involved. TQM is designed to         ​
involve every employee in your company in quality improvement         •   Welcome & Introduction
efforts.                                                              •   Goals of TQM
                                                                      •    Understanding the Principles of Quality
Recommended Audience                                                  •     The TQM Framework
​                                                                     •      Four Key Activities
Senior managers and heads of departments who are responsible          •       Making a Commitment
for making quality happen in the workplace                            •        Planning for TQM
                                                                      •         Putting Systems into Motion
Duration
                                                                      •          Keeping it Going
1 day and 2-day programs are available                                •          Management’s Role in TQM
                                                                      •          Summary & Closing
                                                                      




                                                                                                                            10
                      Operational Excellence Consulting :: Empowering sustainable change
Hoshin Kanri
Description                                                                  Benefits
                                                                             ​
Hoshin Kanri is a powerful, systematic Strategic Planning                    With the discipline of Hoshin Kanri in place, a company can expect
methodology that uses a Plan-Do-Check-Act cycle to create goals,             the following benefits:
choose control measures and link daily control activities to the             ​
company's strategy.                                                          •   Focuses the entire company on a few vital goals, rather than the
                                                                                 trivial many
It involves a "catchball" as the driving force of alignment, clarification   •   Creates alignment towards breakthrough objectives through
and employee involvement.                                                         involvement of the whole management team in the planning
                                                                                  process
The methodology has been used by some of the world’s most                    •    Communicates the key goals to all managers and staff
successful companies such as Toyota, Hewlett-Packard and Bank of             •     Integrates and encourages cross-functional cooperation to
America as a systematic approach to capture and cement strategic                    achieve breakthroughs
goals and develop the means to bring these into reality.                     •      A review process which holds participants accountable for
                                                                                     achieving their part of the plan
Recommended Audience
​
                                                                             Program Outline
Senior executives and heads of departments/sections who are
                                                                             
responsible for the successful achievement of the company shared
                                                                             •   Introduction to Hoshin Kanri
goal
                                                                             •   What is Hoshin Kanri?
Methodology                                                                  •   Underlying Principles of Hoshin Kanri
                                                                             •   Hoshin Kanri Process Using PDCA Approach
Short lectures, individual exercises, group activities and discussions
                                                                             •   Hoshin Kanri Tools
and Q&A
                                                                             •   Elements of Hoshin Kanri
Duration                                                                     •   Management Reviews
                                                                             •   Critical Success Factors
2 days
                                                                             •   Summary & Closing Comments
                                                                             




                                                                                                                                                  11
                                         Operational Excellence Consulting :: Empowering sustainable change
Cost of Quality (COQ)
Description                                                              Learning Objectives
                                                                         ​
As a key factor of competitiveness, cost has to be managed all the       •   To understand the COQ methodology
time, not only in times of economic downturn. The Cost Of Quality        •   To identify major cost components related to the Cost Of Non-
(COQ) program fits well into any operational excellence initiative,          Conformance (CONC) and Cost Of Conformance (COC)
including Lean, Six Sigma and TQM.                                       •   To acquire skills to identify and collect cost and COQ
                                                                             information
The COQ methodology covered in this workshop is a practical
                                                                         •   To analyze the COQ information obtained and relate the data to
approach to quantifying the financial impact of the Cost Of Non-
                                                                             possible solutions that can help reduce COQ in their
Conformance (CONC) and Cost Of Conformance (COC), shifting the
                                                                             organizations
problem-solving focus from quick fix to prevention, and prioritizing
quality improvement opportunities based on the expected financial
return.                                                                  Program Outline

Recommended Audience                                                     •   Introduction & Basic Concepts of COQ
​                                                                        •   Link between quality costing and profits
All senior managers and heads of departments who are responsible         •   Why measure COQ?
for quality improvement                                                  •   What is COQ?
                                                                         •   COQ and Lean & Six Sigma
Methodology
                                                                         •   Key steps in setting up a COQ system
Short lectures, individual exercises, group activities and discussions   •   Preparation for a COQ system
and Q&A                                                                  •   Four phases of a COQ system
                                                                         •   Phase 1: Identifying COQ Items
Duration                                                                 •   Phase 2: Collecting COQ Data

                                                                         •   Phase 3: Analyzing COQ Data
1 day
                                                                         •   Phase 4: Reducing COQ & Improving Quality
                                                                         ​




                                                                                                                         12
                       Operational Excellence Consulting :: Empowering sustainable change
Benchmarking
Description                                                              Benefits
                                                                         ​
Benchmarking is the process of continually searching for the best        •   Explain what benchmarking is
methods, practices and processes, and either adopting or adapting        •    Acquire the benchmarking process know-how based on the
their good features and implementing them to become the “best                  four-phase, ten-step Xerox Benchmarking model
of the best.”                                                            •     Determine the best processes to benchmark to meet your
​                                                                               needs
To become the best-in-class, organizations need to implement the         •      Define the critical success factors in benchmarking
right processes to get there.                                                    implementation
​
This workshop covers the benefits of benchmarking, various types         Program Outline
of benchmarking, identification of what to benchmark, and
provides a detailed step by step guidance on how to systematically       •   Introduction to Benchmarking
carry out a benchmarking project based on the world-renowned             •   What is Benchmarking?
Xerox benchmarking model. It also includes practical tips on the         •   Why Benchmark?
benchmarking process, benchmarking etiquettes and the critical           •   Four Phases of Benchmarking
success factors.                                                         •   Preparation for Benchmarking
                                                                         •   The Benchmarking Process
Recommended Audience                                                     •   Step-by-step: Xerox Benchmarking Process
​                                                                                • Step 1: What to benchmark?
Managers, team leaders and members of benchmarking project                       • Step 2: Whom to benchmark?
teams                                                                            • Step 3: Data collection
                                                                                 • Step 4: Determine current performance “gap”
Methodology                                                                      • Step 5: Project future performance levels
                                                                                 • Step 6: Communicate findings and gain acceptance
Short lectures, individual exercises, group activities and discussions           • Step 7 Establish goals
and Q&A                                                                          • Step 8: Develop action plans
                                                                                 • Step 9: Implement actions and monitor progress
Duration                                                                         • Step 10: Re-calibrate benchmarks
                                                                         •   Do's & Don'ts
1-day and 2-day programs are available                                   •   Critical Success Factors




                                                                                                                                         13
                                        Operational Excellence Consulting :: Empowering sustainable change
Suggestion System
Description                                                              Learning Objectives
                                                                         ​
Employees have lots of ideas, but how do you listen to them? How         •   Learn how to plan and launch a suggestion system
do you harvest their ideas formally and informally, and bubble up        •   Acquire skills in setting up a management infrastructure to
the good ones? How do you generate good quality ideas and                     generate ideas, capture quality ideas, evaluate ideas and sustain
sustain the flow of employee's suggestions to increase customer               a constant flow of ideas
satisfaction, improve bottom line and enhance employee                   •    Learn how to develop employees to identify opportunities for
motivation and enthusiasm?                                                     improvement and write good quality ideas
                                                                         •     Develop supervisors and managers to guide employees in
In this workshop, you will learn how to define the characteristics of
                                                                                writing suggestions
a successful staff suggestion system and establish an infrastructure
to implement and sustain an employee suggestion system that              •      Learn how to recognize and reward participation
provides a constant flow of quality ideas.
                                                                         Program Outline
Recommended Audience
​                                                                        •   Introduction & Basic Concepts
Managers, supervisors and staff suggestion scheme steering               •   Scope of Suggestions
committee members who are responsible for making the scheme              •    Goals of a Suggestion System
successful
                                                                         •     Planning & Launching a Suggestion System
Methodology                                                              •      Roles & Responsibilities of the Suggestions Committee,
                                                                                 Suggestions Office & Department Representatives
Short lectures, individual exercises, group activities and discussions   •       The Suggestions Process
and Q&A                                                                  •        Evaluation & Award Systems
                                                                         •         How to Develop Good Quality Suggestions
Duration                                                                 •          How to Sustain a Suggestion System

1 day




                                                                                                                            14
                       Operational Excellence Consulting :: Empowering sustainable change
Six Sigma Overview
Description                                                                Learning Objectives
                                                                           ​
In today's competitive environment, organizations must delight their       •   Explain how Six Sigma improves business performance
customers and relentlessly look for new ways to exceed their               •   Describe the Six Sigma philosophy and approach to continuous
expectations. To accomplish this, Six Sigma Quality has to become a            improvement
part of an organization’s culture. Six Sigma provides a rigorous and       •   Define process variability
structured approach to help organizations improve their
                                                                           •   Describe the DMAIC improvement methodology
performance in meeting their customers' requirements.
                                                                           •   Recognize which Six Sigma tools to use for a particular problem
This workshop introduces you to the Six Sigma philosophy,                  •   Identify Six Sigma roles and responsibilities, project selection and
methodology and tools and the infrastructure for successful Six                project management to realize the benefits
Sigma deployment without too much of statistical jargon. It includes
applications of Six Sigma in manufacturing, process and service            Program Outline
industries, step-by-step DMAIC improvement approach, phase
description and deliverables, and roles of the Leadership team,            •   Overview of Six Sigma
Champion, Process Owner, Black Belt and Green Belt.                        •   Key Concepts of Six Sigma
​
                                                                           •   Applications of Six Sigma in Manufacturing, Process & Service
Recommended Audience
                                                                               Industries

Senior executives, managers, project champions or project sponsors         •   Six Sigma DMAIC Methodology
​                                                                          •   Six Sigma Toolkit
Methodology                                                                •   Organizing for Six Sigma
                                                                          •   Project Selection and Management
Short lectures, individual exercises, group activities and discussions     •   Critical Success Factors
and Q&A​

Duration: 1 day




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                                         Operational Excellence Consulting :: Empowering sustainable change
Lean Six Sigma Overview

Description                                                              Learning Objectives
                                                                         
Lean Six Sigma provides a rigorous and structured approach to            •   Explain how Lean Six Sigma improves business performance
help organizations improve their performance in meeting their            •   Describe the Lean Six Sigma philosophy and approach to
customers' requirements.                                                     continuous improvement
                                                                         •   Define value, waste, and process variability
This workshop introduces you to the Lean Six Sigma philosophy,
                                                                         •   Explain Lean principles and DMAIC improvement methodology
tools, DMAIC structured problem solving and the infrastructure for
successful Lean Six Sigma deployment. It emphasizes how to lead a        •   Familiarize with Lean Six Sigma tools and their proper use
successful Lean Six Sigma deployment.                                    •   Identify Lean Sigma roles and responsibilities, project selection,
                                                                             measurements, results tracking, and management of project
Recommended Audience                                                         results to sustain the gains

Senior executives, managers, project champions or project                Program Outline
sponsors
​                                                                        •   Introduction to Lean Six Sigma
Methodology                                                              •    Lean Six Sigma Philosophy and Approach to Continuous
                                                                             Improvement
Short lectures, individual exercises, group activities and discussions
                                                                         •    Understanding Value, Waste and Process Variability
and Q&A
                                                                         •    Overview of Lean Principles & Lean “Tools”
Duration                                                                 •    Overview of DMAIC - Six Sigma improvement methodology and
                                                                             tools
1 day                                                                    •    Lean Six Sigma roles and responsibilities
                                                                         •    Deploying Lean Six Sigma into the Organization
                                                                         •    Project selection, measurements, results tracking and
                                                                              management of results to sustain the gains
                                                                         •    Creating and Sustaining a Lean Six Sigma Culture




                                                                                                                             16
                       Operational Excellence Consulting :: Empowering sustainable change
Delivering Service Excellence
Description                                                                Learning Outcomes

In this workshop, you will learn the approach to customer                  •   Understand and accept why and how service excellence is
satisfaction, how to manage your own emotions and deliver                      important to your organization
professional and personalized service, and treat customers as              •   Be able to manage own emotions and deliver professional and
unique individuals with different needs and expectations. It                    personalized service
includes the techniques and skills to find out and respond to each         •    Treat customers as unique individuals with different needs and
customer's needs and expectations, reduce customer's negative                    expectations
feelings and heighten customer's positive feelings towards your            •     Know how to find out and respond to each customer’s needs
organization. Finally, you will learn how to satisfy customers in                 and expectations
comfortable and difficult conditions as well as apply the five A's of      •      Know how to reduce customer’s negative feelings and heighten
service recovery.                                                                  customer’s positive feelings towards the organization
                                                                           •       Learn how to say no to customers in a positive manner
Target Audience
                                                                           •        Be able to apply a recovery process in a difficult situation
This workshop is recommended for frontline staff and supervisors           ​
who interact with your internal and external customers, whether on         Program Outline
the phone, email or face-to-face as well as anyone who requires            
the essential techniques and skills to provide excellent customer          •   Introduction to Delivering Service Excellence
service.                                                                   •   Managing Myself – the Service Provider
                                                                           •    Identifying Customer Condition and Establishing Rapport
Methodology                                                                •     D etermining Customer Needs and Expectations
                                                                           •      Effective Communication Techniques
Short lectures, individual exercises, group activities and discussions,
                                                                           •       Meeting and Exceeding Customer Needs and Expectations
 role plays and Q&A
                                                                           •        Satisfying Customers in Comfortable and Difficult Conditions
Learning Objectives                                                        •         5 Steps of Service Recovery
​                                                                          •          Summary and conclusion
•   To instill in customer service staff the importance of providing
    excellent customer service                                             Duration
•   To equip frontline personnel with effective customer service          ​
     techniques and skills to provide service excellence                   2 days
•    To manage and handle customer interactions and relationships




                                                                                                                                                    17
                                         Operational Excellence Consulting :: Empowering sustainable change
About Operational Excellence Consulting
Who we are

Operational Excellence Consulting helps organizations to work smarter and grow faster. Our work is always evolving to
respond to industry trends and management focus, and we combine our deep technical skills in response to our clients'
changing needs. Over time, what we do remain closely linked with helping our clients improve the way they operate; innovate
and grow; reduce costs; manage risks; leverage talent; and change the way they do business.

One of our unique strengths is going beyond a tools-focused approach to seamlessly integrate people, processes, technology
and continuous improvement initiatives to suit the specific needs and situations of our clients.


What we do

Based in Singapore, we provide corporate learning programs and management advisory services to assist our clients to
achieve breakthrough in business performance and effectiveness. Our aim is to support our clients in designing, managing
and executing lasting beneficial change.


Who we serve

We work with government bodies, multinational corporations and small and medium-sized enterprises of a wide spectrum of
industries. They include public sector, manufacturing, engineering, IT, printing and media, aerospace, defence, financial
services and insurance, education, retail, oil and gas, etc.




                                                                                                                              18
                      Operational Excellence Consulting :: Empowering sustainable change
Contact Us
  Phone:
  +65-6787-8246
  ​
  Email:
  info@oeconsulting.com.sg

  Registered Office:
  28 Simei Street 1, #01-13
  Singapore 529948
  ​
  Business Registration No.:
  53141573B

  Website:
  www.oeconsulting.com.sg




© Operational Excellence Consulting. All rights reserved.

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Operational Excellence Consulting - Training Brochure

  • 2. List of Training Programs ::: Lean Thinking for Transformational Leadership 2 ​ ::: Kaizen​​ 3 ::: 5S & Visual Management 4 ::: Value Stream Mapping 5 ::: Training Within Industry (TWI) 6 ::: PDCA Problem Solving 7 ::: A3 Problem Solving 8 ::: Total Productive Maintenance (TPM)​​ 9 ::: Total Quality Management (TQM) 10 ​::: Hoshin Kanri 11 ::: Cost of Quality​ 12 ::: Benchmarking 13 ::: ​Suggestion System (Kaizen Teian) ​ 14 ::: Six Sigma Overview 15 ::: Lean Six Sigma Overview 16 ​::: Delivering Service Excellence 17 About Operational Excellence Consulting 1 Operational Excellence Consulting :: Empowering sustainable change
  • 3. Lean Thinking for Transformational Leadership Description Methodology ​  Lean (a.k.a. TPS – Toyota Production System) is an organization- Short lectures, individual exercises, group activities and discussions wide continuous improvement initiative that is gaining popularity in and Q&A​ the manufacturing, process and service industries today. Learning Objectives This one-day workshop introduces you to the principles and key  concepts of Lean. You will gain an understanding of productivity • Explain how Lean improves business performance loss from the three major sources of waste: • Describe the Lean principles and approach to continuous improvement (1) Non-value added work, • Define value and waste (2) Process variability and • Understand the applications of the Lean principles and Lean (3) Process/System inflexibility (bottlenecks) "tools" • Define the role of the Lean Leader In addition, you will learn how Lean principles and tools can be • Define the critical success factors in starting and sustaining a applied to eliminate non-value added work, create stable processes Lean culture and mistake-proof operations so as to significantly improve productivity and increase value to customers. Program Outline  As a senior executive, you will gain a deeper insight into your role • Introduction to Lean as a Lean Leader and create the right conditions to start and • Productivity Loss is Caused by Three Major Sources of Waste sustain a successful Lean program. • Examples of Lean Adoption in Manufacturing and Service ​ Environments Recommended Audience • Lean Principles and Approach to Creating Customer Value  • Lean and Six Sigma Senior executives, managers, project champions or project • Understanding Value and Waste sponsors of manufacturing and service industries who are • Key Lean “Tools” interested in getting a “big picture” perspective of Lean before • The Lean Framework  embarking on the detailed planning and implementation • Role of the Lean Leader • Key Considerations in Developing a Lean Infrastructure Duration: 1 day • Developing "Kaizen Eyes" • Sustaining a Lean Culture 2 Operational Excellence Consulting :: Empowering sustainable change
  • 4. Kaizen Description Methodology Kaizen strategy is the single most important concept in Japanese Short lectures, individual exercises, group activities and discussions management – the key to successful Japanese companies such as and Q&A Toyota. Learning Objectives Based on Masaaki Imai's teachings on 'Kaizen' and 'Gemba Kaizen', ​ this workshop is specially designed for managers and supervisors • Explain the key concepts of Kaizen who are interested in developing a Kaizen culture in the workplace • Manage Kaizen activities as a means to eliminate waste and and facilitating Kaizen events as a mechanism to improve operational provide increased value to customers efficiency. • Learn the key tools and techniques in the Kaizen approach to problem solving Participants will learn the key concepts and benefits of Kaizen and • D efine the key steps in conducting a Kaizen event how to manage Kaizen in their work areas to improve productivity • Explain the role of management in managing Kaizen activities and customer value. This workshop will enable participants to • ​Understand the critical success factors in sustaining Kaizen understand the key tools and techniques for running Kaizen activities activities on a daily basis, problem solving, conducting a Kaizen event as well as overcoming barriers to successful implementation. Program Outline  Recommended Audience • Introduction to Kaizen ​ Managers, supervisors, facilitators and Continuous Improvement • Kaizen & Waste steering committee members responsible for deploying Kaizen in the • Key Concepts of Kaizen work areas • Kaizen Management • Kaizen Practices Duration • Kaizen Implementation  • Problem Solving 1-day and 2-day programs are available • Developing “Kaizen Eyes” • Role of Management • Critical Success Factors ​ 3 Operational Excellence Consulting :: Empowering sustainable change
  • 5. 5S & Visual Management Description Learning Objectives ​ 5S good housekeeping and workplace organization is a set of basic • Understand the importance and benefits of 5S management principles that are widely adopted in industries • Define each of the 5S principles, and identify types of visual today. As a foundation of Lean management, the key targets of 5S management are improved workplace efficiency, morale and safety. • Explain how to implement each of the 5S principles • Explain how to apply 5S in the office In this workshop, you will learn how to mobilize and align your management team to launch or improve a 5S and Visual • Identify the infrastructure necessary for starting and sustaining Management implementation in your organization. The workshop a 5S initiative in your organization covers 5S and Visual Management best practices, step-by-step • Define the critical success factors for 5S implementation implementation guidance, and the best ways to integrate 5S into the organization’s culture to achieve sustainable world-class Program Outline​ excellence. It includes the principles of 5S and Visual Management and the benefits, initial implementation, future refinement, self- • Introduction & Overview of 5S assessment as well as the infrastructure necessary to start and • What is 5S? sustain a 5S initiative for your organization. • Why 5S? • 5S as a Foundation of Lean Management Recommended Audience • 5S Principles - 1S: Sort (Seiri) Managers, supervisors and 5S steering committee members - 2S: Set In Order (Seiton)​ Methodology - 3S: Shine (Seiso)  - 4S: Standardize (Seiketsu) Short lectures, individual exercises, group activities and discussions - 5S: Sustain (Shitsuke) and Q&A • Visual Management ​ • 5S Applications in Safety, Quality, Reliability & Waste ​Duration • 5S in the Office  • Starting, Launching & Promoting a 5S Initiative 1 day • Supporting Lean Tools for 5S Implementation • Critical Success Factors  4 Operational Excellence Consulting :: Empowering sustainable change
  • 6. Value Stream Mapping This workshop provides a step-by-step instruction to enable ​Methodology participants to create current state and future state value stream maps, and to identify opportunities to achieve the future state that Short lectures, individual exercises, group activities and discussions have the greatest impacts on the business as well as customer and Q&A value.​ You will learn how the critical tool of value stream mapping and analysis helps your organization see waste and opportunities, Program Outline and envision a Lean future state. • Key Principles of Lean Recommended Audience • Understanding Value, Wastes & Inflexibility ​ • Overview of Lean Methodology & Tools Managers, supervisors, Lean practitioners and staff • Introduction to Value Stream Mapping, Tools and Symbols Learning Objectives • Identifying a Business Value Stream • Step-by-Step Approach to Value Stream Mapping ​Upon completion of this workshop, participants will be able to: • Assessing Value-Added and Non-Value-Added Activities • Defining Goals and Gaps • Map a current-state value stream • Definition of the Future State Value Stream • Develop a data collection plan for the value stream map • Using Value Stream Map to Identify Lean Improvement Projects • Conduct end-to-end assessment of value-added versus non- • Prioritizing & Selecting Lean Projects value-added activities • Define Actions to Close Gap • Scope opportunities by framing project problem statements based on identified waste  Duration • Prioritize project based on strategic objectives • Develop action plan to achieve the future state 2 days • Envision the Lean future state and create the future-state value stream map • Engage other teams in mapping their processes and surfacing more opportunities for improvement 5 Operational Excellence Consulting :: Empowering sustainable change
  • 7. Training Within Industry (TWI) Training Within Industry (TWI) is an integral part of Lean to Recommended Audience reinforce the practice of Standard Work. Standardized work Supervisors, Line Leaders, Charge-hands, Trainers and Assistant eliminates waste, improves process stability and provides a baseline Foremen from manufacturing companies for process improvement. Methodology Program Objectives Short lectures, discussions and practice demonstrations Job Relations (JR): To lead people by effectively and positively dealing with relationship problems between the supervisor and the Program Outline employee, and preventing these problems from developing in the first place by maintaining positive employee relationships. • Overview and Introduction • Role of Supervisors in Lean Manufacturing Job Instruction (JI): To provide proper training and assuring this • Five Needs of Good Supervisors training is effective in helping people do their jobs correctly and • Job Instruction (JI) efficiently. Four Steps for Job Instruction Four Steps to Get Ready Job Methods (JM): To improve processes and the workplace by Job Breakdown – Important Steps, Key Points & Reasons developing improvement proposals and implementing them to get Training Timetables improved results. Special Instruction Problems (and how to handle them) Job Instruction & Standard Work Benefits • Job Methods (JM) • Get more done with less machines and manpower Four Steps for Job Methods Improvement • Improve quality, reduce scrap by achieving standard work Job Breakdown Sheet across workers and shifts 5W’s & 1H • Reduce safety incidents Eliminate, Combine, Rearrange & Simplify • Decrease training time, especially for temporary workers Job Method Improvement Proposal Sheet • Reduce labor hours Resistance & Resentment • Reduce grievances • Job Relations (JR) • Transfer knowledge from a skilled workforce to an unskilled or Chart on Supervisory Responsibility green workforce Foundations for Good Relations Chart on the Individual Duration: 2 days How Problems Arise Four Steps for Job Relations • Sustaining TWI 6 Operational Excellence Consulting :: Empowering sustainable change
  • 8. PDCA Problem Solving Description Methodology How do you solve business problems that are cross-functional and Short lectures, individual exercises, group activities and discussions there is not a single subject matter expert who has sufficient and Q&A knowledge about the real causes of the problem? How do you break through the functional silos to obtain a detailed understanding of the current processes and then develop a future state process that Learning Objectives involves all departments and gives you the true nature of the problem to be solved? • Understand the principles and key concepts of problem solving  • Learn how to apply the PDCA approach and basic quality tools to In this workshop, you will learn the structured Plan-Do-Check-Act • problem solving (PDCA) approach to problem solving. The PDCA problem solving • Learn how to prepare an A3 problem solving report process is a technique that is used by Toyota to identify problems, analyze root causes and generate solutions. When combined with • Understand the roles of problem solving team the basic quality ("QC") tools, real causes to business problems can • Define the critical success factors for effective problem solving be identified and effective solutions can be put in place to prevent similar problems from recurring in the future. Program Outline Recommended Audience • Introduction to Problem Solving ​ • Concept of Problem Solving Teams Any manager or staff who is interested in facilitating, leading or • Overview of Process Management participating in a problem solving project • PDCA Approach to Problem Solving • Problem Solving Tools Duration • Examples & Practice Tips  • Project Reporting Using A3 Storyboard 2 Days • 10 Common Mistakes​ • Critical Success Factors  7 Operational Excellence Consulting :: Empowering sustainable change
  • 9. A3 Problem Solving Description Learning Objectives ​  In this workshop, participants will learn the structured problem- • Identify the types of wastes that contribute to workplace solving approach that uses a tool called the A3 Problem-Solving inefficiency Report. The A3 report is a tool that Toyota uses to propose • D efine the benefits of the A3 report solutions to problems, give status reports on ongoing projects, and • Carry out the A3 problem solving process report results of information gathering activity. The term "A3" is • Perform root cause analysis derived from the paper size used for the report, which is the metric • Make a clear and concise A3 report equivalent to the 11" x 17" paper. ​ ​ Program Outline You will learn the steps to proceed from problem identification to resolution in a fashion that fosters learning, collaboration, and • Introduction to Lean personal development. The problem-solving team records the • Overview of the Types of Waste results of investigation and planning in a concise, two-page • What is the A3 Report document (the A3 Report) that facilitates knowledge sharing and • Why use the A3 Report collaboration. • The A3 Problem Solving Process - Step-by-step - Identify a problem or need Recommended Audience - Conduct research to understand the current situation ​ - Conduct root cause analysis Lean managers, operations/production managers, engineers and - Devise countermeasures to address root causes practitioners - Develop a target state - Create an implementation plan Methodology - Develop a follow-up plan with predicted outcomes - Discuss plans with all affected parties Short lectures, individual exercises, group activities and discussions - Obtain approval for implementation and Q&A - Implement plans - Evaluate the results Duration • Common Mistakes to Avoid • Critical Success Factors 2 Days • Workshop: Making Your A3 Report • ​Conclusion and Wrap-up  8 Operational Excellence Consulting :: Empowering sustainable change
  • 10. Total Productive Maintenance (TPM) Description Methodology ​  Total Productive Maintenance (TPM), is a company-wide initiative Short lectures, individual exercises, group activities and discussions for maximizing the effectiveness of equipment. The goal of the and Q&A​ TPM program is to significantly increase labor and capital productivity while, at the same time, increasing employee morale Program Outline and job satisfaction. TPM brings maintenance into focus as a  necessary and vitally important part of the business. Targeted at all • Overview of TPM levels of the organization, TPM and its 8 pillars provide the • TPM Foundations – 5S & Visual Management necessary process and tools to achieve zero defects, zero • TPM Tools breakdowns and zero accidents. • Equipment Loss & Overall Equipment Effectiveness (OEE) Recommended Audience • The 8 Pillars of TPM ​ - Autonomous Maintenance Managers, engineers, supervisors, TPM steering committee and - Planned Maintenance other operational staff from production, engineering and - Early Equipment Management maintenance - Focused Improvement - Quality Maintenance Learning Objectives - Education and Training  - TPM in the Office • Understand the concept and management philosophy of TPM - Safety & Environmental Management as a foundation for Lean Transformation • Improving Equipment Reliability through Integration of • Learn the 8 pillars of TPM activities, TPM implementation Autonomous Maintenance & Planned Maintenance strategy, roadmap and step-by-step approach • TPM Roles and Responsibilities • Learn the TPM tools and be able to identify and eliminate loss • TPM Planning & Implementation through TPM implementation • Critical Success Factors for TPM Implementation • Understand the Autonomous Maintenance process and how to improve equipment reliability Duration • Understand the roles of a TPM implementation organization and the critical success factors 1-day and 2-day programs are available 9 Operational Excellence Consulting :: Empowering sustainable change
  • 11. Total Quality Management (TQM) Description Methodology This workshop is designed to help you, as a key manager, Short lectures, individual exercises, group activities and discussions understand how to approach quality as a company-wide and Q&A effort. You will learn how to make a commitment, plan and begin to implement systems for managing quality that integrates all the Learning Objectives people, processes and continuous improvement initiatives together. • Explain the Principles of Quality • Describe the TQM framework (“House of Quality”) Based on Philip Crosby's methodology, this workshop introduces • D efine the Four Key Activities for managing quality participants to the Five Quality Principles and the Four Key • Explain the need for a culture change, starting at the top Activities for Quality Management. • D emonstrate a personal commitment to total quality • Explain the TQM implementation infrastructure Finally, the role of the manager will be examined so as to identify • D escribe how to put the systems for TQM into motion what you, personally, can do to plan the improvement process and communicate the need to change. • Identify ways to sustain TQM activities • Understand a manager’s role in quality improvement To manage and improve quality, a long-term commitment of time and effort will be required. For these efforts to succeed, every Program Outline employee in the company must get involved. TQM is designed to ​ involve every employee in your company in quality improvement • Welcome & Introduction efforts. • Goals of TQM • Understanding the Principles of Quality Recommended Audience • The TQM Framework ​ • Four Key Activities Senior managers and heads of departments who are responsible • Making a Commitment for making quality happen in the workplace • Planning for TQM • Putting Systems into Motion Duration • Keeping it Going 1 day and 2-day programs are available • Management’s Role in TQM • Summary & Closing  10 Operational Excellence Consulting :: Empowering sustainable change
  • 12. Hoshin Kanri Description Benefits ​ Hoshin Kanri is a powerful, systematic Strategic Planning With the discipline of Hoshin Kanri in place, a company can expect methodology that uses a Plan-Do-Check-Act cycle to create goals, the following benefits: choose control measures and link daily control activities to the ​ company's strategy. • Focuses the entire company on a few vital goals, rather than the trivial many It involves a "catchball" as the driving force of alignment, clarification • Creates alignment towards breakthrough objectives through and employee involvement. involvement of the whole management team in the planning process The methodology has been used by some of the world’s most • Communicates the key goals to all managers and staff successful companies such as Toyota, Hewlett-Packard and Bank of • Integrates and encourages cross-functional cooperation to America as a systematic approach to capture and cement strategic achieve breakthroughs goals and develop the means to bring these into reality. • A review process which holds participants accountable for achieving their part of the plan Recommended Audience ​ Program Outline Senior executives and heads of departments/sections who are  responsible for the successful achievement of the company shared • Introduction to Hoshin Kanri goal • What is Hoshin Kanri? Methodology • Underlying Principles of Hoshin Kanri • Hoshin Kanri Process Using PDCA Approach Short lectures, individual exercises, group activities and discussions • Hoshin Kanri Tools and Q&A • Elements of Hoshin Kanri Duration • Management Reviews • Critical Success Factors 2 days • Summary & Closing Comments  11 Operational Excellence Consulting :: Empowering sustainable change
  • 13. Cost of Quality (COQ) Description Learning Objectives ​ As a key factor of competitiveness, cost has to be managed all the • To understand the COQ methodology time, not only in times of economic downturn. The Cost Of Quality • To identify major cost components related to the Cost Of Non- (COQ) program fits well into any operational excellence initiative, Conformance (CONC) and Cost Of Conformance (COC) including Lean, Six Sigma and TQM. • To acquire skills to identify and collect cost and COQ information The COQ methodology covered in this workshop is a practical • To analyze the COQ information obtained and relate the data to approach to quantifying the financial impact of the Cost Of Non- possible solutions that can help reduce COQ in their Conformance (CONC) and Cost Of Conformance (COC), shifting the organizations problem-solving focus from quick fix to prevention, and prioritizing quality improvement opportunities based on the expected financial return. Program Outline Recommended Audience • Introduction & Basic Concepts of COQ ​ • Link between quality costing and profits All senior managers and heads of departments who are responsible • Why measure COQ? for quality improvement • What is COQ? • COQ and Lean & Six Sigma Methodology • Key steps in setting up a COQ system Short lectures, individual exercises, group activities and discussions • Preparation for a COQ system and Q&A • Four phases of a COQ system • Phase 1: Identifying COQ Items Duration • Phase 2: Collecting COQ Data  • Phase 3: Analyzing COQ Data 1 day • Phase 4: Reducing COQ & Improving Quality ​ 12 Operational Excellence Consulting :: Empowering sustainable change
  • 14. Benchmarking Description Benefits ​ Benchmarking is the process of continually searching for the best • Explain what benchmarking is methods, practices and processes, and either adopting or adapting • Acquire the benchmarking process know-how based on the their good features and implementing them to become the “best four-phase, ten-step Xerox Benchmarking model of the best.” • Determine the best processes to benchmark to meet your ​ needs To become the best-in-class, organizations need to implement the • Define the critical success factors in benchmarking right processes to get there. implementation ​ This workshop covers the benefits of benchmarking, various types Program Outline of benchmarking, identification of what to benchmark, and provides a detailed step by step guidance on how to systematically • Introduction to Benchmarking carry out a benchmarking project based on the world-renowned • What is Benchmarking? Xerox benchmarking model. It also includes practical tips on the • Why Benchmark? benchmarking process, benchmarking etiquettes and the critical • Four Phases of Benchmarking success factors. • Preparation for Benchmarking • The Benchmarking Process Recommended Audience • Step-by-step: Xerox Benchmarking Process ​ • Step 1: What to benchmark? Managers, team leaders and members of benchmarking project • Step 2: Whom to benchmark? teams • Step 3: Data collection • Step 4: Determine current performance “gap” Methodology • Step 5: Project future performance levels • Step 6: Communicate findings and gain acceptance Short lectures, individual exercises, group activities and discussions • Step 7 Establish goals and Q&A • Step 8: Develop action plans • Step 9: Implement actions and monitor progress Duration • Step 10: Re-calibrate benchmarks • Do's & Don'ts 1-day and 2-day programs are available • Critical Success Factors 13 Operational Excellence Consulting :: Empowering sustainable change
  • 15. Suggestion System Description Learning Objectives ​ Employees have lots of ideas, but how do you listen to them? How • Learn how to plan and launch a suggestion system do you harvest their ideas formally and informally, and bubble up • Acquire skills in setting up a management infrastructure to the good ones? How do you generate good quality ideas and generate ideas, capture quality ideas, evaluate ideas and sustain sustain the flow of employee's suggestions to increase customer a constant flow of ideas satisfaction, improve bottom line and enhance employee • Learn how to develop employees to identify opportunities for motivation and enthusiasm? improvement and write good quality ideas • Develop supervisors and managers to guide employees in In this workshop, you will learn how to define the characteristics of writing suggestions a successful staff suggestion system and establish an infrastructure to implement and sustain an employee suggestion system that • Learn how to recognize and reward participation provides a constant flow of quality ideas. Program Outline Recommended Audience ​ • Introduction & Basic Concepts Managers, supervisors and staff suggestion scheme steering • Scope of Suggestions committee members who are responsible for making the scheme • Goals of a Suggestion System successful • Planning & Launching a Suggestion System Methodology • Roles & Responsibilities of the Suggestions Committee, Suggestions Office & Department Representatives Short lectures, individual exercises, group activities and discussions • The Suggestions Process and Q&A • Evaluation & Award Systems • How to Develop Good Quality Suggestions Duration • How to Sustain a Suggestion System  1 day 14 Operational Excellence Consulting :: Empowering sustainable change
  • 16. Six Sigma Overview Description Learning Objectives ​ In today's competitive environment, organizations must delight their • Explain how Six Sigma improves business performance customers and relentlessly look for new ways to exceed their • Describe the Six Sigma philosophy and approach to continuous expectations. To accomplish this, Six Sigma Quality has to become a improvement part of an organization’s culture. Six Sigma provides a rigorous and • Define process variability structured approach to help organizations improve their • Describe the DMAIC improvement methodology performance in meeting their customers' requirements. • Recognize which Six Sigma tools to use for a particular problem This workshop introduces you to the Six Sigma philosophy, • Identify Six Sigma roles and responsibilities, project selection and methodology and tools and the infrastructure for successful Six project management to realize the benefits Sigma deployment without too much of statistical jargon. It includes applications of Six Sigma in manufacturing, process and service Program Outline industries, step-by-step DMAIC improvement approach, phase description and deliverables, and roles of the Leadership team, • Overview of Six Sigma Champion, Process Owner, Black Belt and Green Belt. • Key Concepts of Six Sigma ​ • Applications of Six Sigma in Manufacturing, Process & Service Recommended Audience Industries  Senior executives, managers, project champions or project sponsors • Six Sigma DMAIC Methodology ​ • Six Sigma Toolkit Methodology • Organizing for Six Sigma  • Project Selection and Management Short lectures, individual exercises, group activities and discussions • Critical Success Factors and Q&A​ Duration: 1 day 15 Operational Excellence Consulting :: Empowering sustainable change
  • 17. Lean Six Sigma Overview Description Learning Objectives  Lean Six Sigma provides a rigorous and structured approach to • Explain how Lean Six Sigma improves business performance help organizations improve their performance in meeting their • Describe the Lean Six Sigma philosophy and approach to customers' requirements. continuous improvement • Define value, waste, and process variability This workshop introduces you to the Lean Six Sigma philosophy, • Explain Lean principles and DMAIC improvement methodology tools, DMAIC structured problem solving and the infrastructure for successful Lean Six Sigma deployment. It emphasizes how to lead a • Familiarize with Lean Six Sigma tools and their proper use successful Lean Six Sigma deployment. • Identify Lean Sigma roles and responsibilities, project selection, measurements, results tracking, and management of project Recommended Audience results to sustain the gains  Senior executives, managers, project champions or project Program Outline sponsors ​ • Introduction to Lean Six Sigma Methodology • Lean Six Sigma Philosophy and Approach to Continuous  Improvement Short lectures, individual exercises, group activities and discussions • Understanding Value, Waste and Process Variability and Q&A • Overview of Lean Principles & Lean “Tools” Duration • Overview of DMAIC - Six Sigma improvement methodology and  tools 1 day • Lean Six Sigma roles and responsibilities • Deploying Lean Six Sigma into the Organization • Project selection, measurements, results tracking and management of results to sustain the gains • Creating and Sustaining a Lean Six Sigma Culture 16 Operational Excellence Consulting :: Empowering sustainable change
  • 18. Delivering Service Excellence Description Learning Outcomes In this workshop, you will learn the approach to customer • Understand and accept why and how service excellence is satisfaction, how to manage your own emotions and deliver important to your organization professional and personalized service, and treat customers as • Be able to manage own emotions and deliver professional and unique individuals with different needs and expectations. It personalized service includes the techniques and skills to find out and respond to each • Treat customers as unique individuals with different needs and customer's needs and expectations, reduce customer's negative expectations feelings and heighten customer's positive feelings towards your • Know how to find out and respond to each customer’s needs organization. Finally, you will learn how to satisfy customers in and expectations comfortable and difficult conditions as well as apply the five A's of • Know how to reduce customer’s negative feelings and heighten service recovery. customer’s positive feelings towards the organization • Learn how to say no to customers in a positive manner Target Audience • Be able to apply a recovery process in a difficult situation This workshop is recommended for frontline staff and supervisors ​ who interact with your internal and external customers, whether on Program Outline the phone, email or face-to-face as well as anyone who requires  the essential techniques and skills to provide excellent customer • Introduction to Delivering Service Excellence service. • Managing Myself – the Service Provider • Identifying Customer Condition and Establishing Rapport Methodology • D etermining Customer Needs and Expectations • Effective Communication Techniques Short lectures, individual exercises, group activities and discussions, • Meeting and Exceeding Customer Needs and Expectations role plays and Q&A • Satisfying Customers in Comfortable and Difficult Conditions Learning Objectives • 5 Steps of Service Recovery ​ • Summary and conclusion • To instill in customer service staff the importance of providing excellent customer service Duration • To equip frontline personnel with effective customer service ​ techniques and skills to provide service excellence 2 days • To manage and handle customer interactions and relationships 17 Operational Excellence Consulting :: Empowering sustainable change
  • 19. About Operational Excellence Consulting Who we are Operational Excellence Consulting helps organizations to work smarter and grow faster. Our work is always evolving to respond to industry trends and management focus, and we combine our deep technical skills in response to our clients' changing needs. Over time, what we do remain closely linked with helping our clients improve the way they operate; innovate and grow; reduce costs; manage risks; leverage talent; and change the way they do business. One of our unique strengths is going beyond a tools-focused approach to seamlessly integrate people, processes, technology and continuous improvement initiatives to suit the specific needs and situations of our clients. What we do Based in Singapore, we provide corporate learning programs and management advisory services to assist our clients to achieve breakthrough in business performance and effectiveness. Our aim is to support our clients in designing, managing and executing lasting beneficial change. Who we serve We work with government bodies, multinational corporations and small and medium-sized enterprises of a wide spectrum of industries. They include public sector, manufacturing, engineering, IT, printing and media, aerospace, defence, financial services and insurance, education, retail, oil and gas, etc. 18 Operational Excellence Consulting :: Empowering sustainable change
  • 20. Contact Us Phone: +65-6787-8246 ​ Email: info@oeconsulting.com.sg Registered Office: 28 Simei Street 1, #01-13 Singapore 529948 ​ Business Registration No.: 53141573B Website: www.oeconsulting.com.sg © Operational Excellence Consulting. All rights reserved.