Operational Excellence

Courses and Workshops in GP's Robust Approach

• Essentials - Rapid Assessment (1 day)
  Interactive workshop focusing on the principles, methods, roles, and various approaches for rolling out business change. Attendees will learn to perform Levels of Achievement using Rapid Assessment.
• Leadership Alignment Workshop (2 days)
  Interactive workshop including content of Rapid Assessment during Day 1. Day 2 covers assessing current performance, agreeing to a vision, and planning a roll-out for change.
• Boot Camp for Internal Consultants (5 days)
  One-week session which expands the content of the Leadership Alignment Workshop with case studies, practice sessions, Rapid Improvement™ methodology, and consulting skills.
• Lean Six Sigma for Champions and Sponsors (3 days)
  Overview of Lean Six Sigma including planning, integration & implementation principles. The roles of the champion, senior managers, and “belts” will be defined. Problem solving and statistical tools will be introduced along with DMAIC project management.
• Lean Six Sigma for Green Belts (8 days
  (4 days/month x 2 months))
  Course includes over 30 interactive workshops using the Six Sigma Reference Guide as the Pathway to Excellence. Process improvement and statistical tools will be introduced. Attendees will learn to be proficient in project management.
• Lean Six Sigma for Black Belts (16 days
  (4 days/month x 4 months))
  DMAIC project & team management skills will be introduced. Tools covering process improvement, advanced statistics, project management and change management will be covered in detail, along with project-based learning mentored by qualified experts. Considerable focus spent on the application of the various tools using both a self-study Reference Guide and class time.
• Five S (5S) Leader Seminar and Rapid Improvement Workshop (3 days)
  5S Leader Seminar and 5S Rapid Improvement Workshop includes a presentation of 5S principles and planning for the implementation. It continues with a self-audit and discussion of what 5S in practice could look like in your organization. Day 2 and 3 entail detailed planning for and implementation of a two-day 5S Rapid Improvement Workshop. During the Workshop, your 5S Champions and our consultant co-lead employees in a work group as they “5S” their area. By the end of the Workshop the employees have removed unneeded items, organized necessary items according to frequency of use, set required quantities, established visual controls, and developed work standards and necessary actions to assure sustainability.
• Root Cause Failure Analysis (2 days)
  Interactive workshop introducing a 9-step process for in-depth problem solving analysis. Attendees will initially learn the importance of performing root cause failure analysis. The root cause of a problem will be identified using the problem solving process, along with the application of basic quality tools throughout the problem solving process.
• Maintenance Planning and Scheduling Using Lean Principles (3 days)
  Course material includes definition of Proactive Maintenance and why it is important. The elements of an overall Equipment Reliability System will be covered with detail discussion on the Maintenance Work Cycle. Attendees will learn how to develop a long-range base-load work plan, implement a 6-wk "look-ahead" planning & scheduling horizon and the importance of both daily & weekly maintenance reviews. Lean principles will be used throughout the course to highlight waste & identify opportunities for improvement.
• Outage Planning Using Lean Principles (4 days)
  Course covers the "best practices" in outage planning across a variety of industrial sectors including the development of a management standard, tools and templates. Attendees will then learn to apply these principles on a case study and generate a "current state" map of the existing outage planning process. Applying lean thinking, waste and opportunities will be identified. From this, a stream-lined vision of the "future state" process will be developed and applied to the case study.
• Daily Management - The Foundation for Continuous Improvement (2 days)
  This course covers an emerging approach with focus on the Daily Management component of an overall Business System. Tools will be covered that assure process control, maintain & incrementally improve day-to-day results and encourage the involvement of all employees. Attendees will become knowledgeable about the five requirements for successful implementation of Daily Management.
• Daily Management - The Foundation for Equipment Reliability (2 days)
  This course covers the Daily Management component of an overall Equipment Reliability System. Topics in both Operations and Maintenance include: standardized work practices, training, auditing work, failure analysis, solicitation of ideas to incrementally improve day-to-day reliability, and communication.
• Model Area Transformation (100 - 150 days)
  An extended project to produce a model of excellence pilot area and quantum leap performance improvement. Starts with Rapid Assessment and Leadership Alignment Workshops. Implements the plan agreed to during the Alignment Workshop by applying the methods of Lean Manufacturing, Six Sigma, Total Productive Maintenance, Goal Deployment, and Daily Management. Results in millions of dollars of bottom line improvement, certification for Black Belts, and the capability to sustain and continuously improve.