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Understanding Process Improvement And Root-cause Analysis
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Course Overview
This 40-hour course provides participants with practical tools and methodologies to enhance organizational processes and systematically identify and address root causes of problems. Designed for business leaders, managers, process improvement teams, and quality professionals, this course emphasizes continuous improvement, efficiency, and operational excellence.
Course Modules
Module 1
3 hours
Introduction to Process Improvement
Definition and Importance of Process Improvement - Benefits of Continuous Improvement - Overview of Process Improvement Methodologies (Lean, Six Sigma, Kaizen)
Objectives: Understand the purpose and benefits of process improvement.
Assessment: Introductory quiz.
Module 2
3 hours
Understanding Business Processes
Process Mapping and Flowcharting - Identifying Key Processes and Stakeholders - Value Stream Mapping
Objectives: Map and analyze business processes.
Assessment: Process mapping assignment.
Module 3
4 hours
Principles of Lean Thinking
Lean Principles and Waste Elimination - The 5S System - Value vs. Non-Value Activities
Objectives: Apply Lean principles to streamline processes.
Assessment: Lean analysis case study.
Module 4
3 hours
Introduction to Six Sigma
DMAIC Framework (Define, Measure, Analyze, Improve, Control) - Tools for Data-Driven Process Improvement - Understanding Variability and Defects
Objectives: Gain a foundational understanding of Six Sigma.
Assessment: Six Sigma mini-project.
Module 5
4 hours
Root Cause Analysis Techniques
The 5 Whys Technique - Fishbone (Ishikawa) Diagrams - Pareto Analysis
Objectives: Identify and analyze root causes of problems.
Assessment: Root cause analysis exercise.
Module 6
3 hours
Problem-Solving Frameworks
PDCA (Plan-Do-Check-Act) Cycle - A3 Problem-Solving Method - TRIZ (Theory of Inventive Problem Solving)
Objectives: Apply structured problem-solving methodologies.
Assessment: Problem-solving workshop.
Module 7
3 hours
Data Collection and Analysis
Types of Data in Process Improvement - Statistical Tools for Analysis - Using Control Charts
Objectives: Collect and analyze data effectively.
Assessment: Data analysis assignment.
Module 8
4 hours
Process Improvement Tools and Techniques
Process Flow Analysis - Failure Modes and Effects Analysis (FMEA) - Kaizen Events
Objectives: Utilize various process improvement tools.
Assessment: Tool application case study.
Module 9
3 hours
Change Management in Process Improvement
Overcoming Resistance to Change - Engaging Stakeholders - Communication Strategies
Objectives: Manage change effectively within improvement initiatives.
Assessment: Change management strategy proposal.
Module 10
3 hours
Sustaining Process Improvements
Establishing Standard Operating Procedures (SOPs) - Continuous Monitoring and Feedback Loops - Culture of Continuous Improvement
Objectives: Ensure long-term sustainability of improvements.
Assessment: Sustainability plan development.
Module 11
3 hours
Case Studies in Process Improvement
Real-World Examples of Successful Improvements - Lessons Learned from Failures - Industry-Specific Best Practices
Objectives: Learn from practical examples and case studies.
Assessment: Case study analysis
Module 12
4 hours
Final Project and Course Review
Comprehensive Process Improvement Plan - Root Cause Analysis on a Selected Problem - Final Assessment and Feedback
Objectives: Apply all course concepts to a practical scenario.
Assessment: Final project presentation.