Production Academy

The Production Academy is a set of eight training and consulting modules from which leading specialists of manufacturing companies can choose the most appropriate ones to find solutions to the following operational challenges of manufacturing companies:

• Employee shortage - how to do more with fewer employees?

• Raw material availability - how to organize the supply of raw materials for a smoother production flow?

• Downtime - how to organize production planning to reduce downtime and losses?

• Price competition - understand which products and what discounts can be given, which products can be priced higher?

• Backorders - how to increase production speed without increasing capacity?

• Warehouse balances - how to produce more without additional investments in equipment or opening a new shift?

Program

1. Fundamentals of production and process management, 8 hours

• What is production flow?

• The most important elements of production flow.

• Concepts and measurements of production flow.

• Optimization and goals of the production process.

• The most important production optimization methodologies

• (LEAN, TOC, SixSigma)

• Fundamentals of LEAN methodology: MUDA, 5S. Practical work.

• Fundamentals of TOC methodology: constraint management.

• Interdependence of production and other departments.

2. Production flow and its management, 8 hours

• Types of production flow - to order, to warehouse.

• Computer simulation of production flow.

• Business simulation “Efficiency syndrome”.

• Balanced production line. Business simulation “Dice game”.

• Flow management according to LEAN.

• Flow management according to TOC.

• Production plan development.

• Optimal batch. Business simulation “Signature production”.

• The role of IT in production optimization.

3. Warehouse and inventory flow management, 8 hours

• The most important elements of inventory flow.

• Inventory flow optimization and goals.

• Supply chain simulation game “Beer Game”.

• Inventory flow forecasting. Practical tasks.

• Inventory management methodologies VMI, Replenish, DBM.

• Warehouse flow management with TOC and LEAN.

4. New product development and project management optimization, 8 hours

• Technology readiness levels and their importance in product implementation. Practical work.

• Justification of the need for new product development - profit, market penetration, competitiveness improvement, capacity utilization.

• Defining the new product development process and goals. Practical work.

• Project management principles and challenges.

• Challenges of simultaneous product management.

• Project management methodology according to TOC.

  
  

5. Financial management and optimization of a manufacturing company, 8 hours

• Elements of financial management.

• Goals of financial management optimization.

• Linking financial management with other company departments - production, sales, procurement,

• Simple cost calculation methodologies.

• Pricing methodologies for maintaining maximum margins for new and existing products. Price differentiation.

• Purchase price analysis and decision-making.

• Decision-making on the volume of inventory in warehouses.

• Development of unifying KPIs for the company and their adaptation to the needs and goals of individual departments.

• Internal communication of financial results.

6. Sales flow management and optimization, 8 hours

• Goals of the sales system in a manufacturing company.

• Creation of sales flow. Practical work.

• Determination of sales flow performance indicators. Practical work.

• Providing sales flow with the necessary resources. Practical work.

• Sales process management, analysis and optimization.

7. Optimization of motivation and remuneration system, 8 hours

• Goals of motivation system in a manufacturing company

• Linking motivation system with production, sales and financial goals

• The most important elements of the motivation system

• Criteria and mechanisms for evaluating the work and knowledge invested

• Measurements for promoting work efficiency.

• Basics of remuneration and motivation in different departments - production, sales, warehouse, management, etc.

8. Creation of a culture of optimization and innovation, 8 hours

• KAIZEN - the basics of continuous improvement management methodology.

• The dilemma of employee duties and rights. Solutions.

• Weekly planning meetings, their goals, content and procedure

• The importance and content of information boards. Practical work

• The dilemma of raising employee initiative. Solutions.

• A plan for creating a culture of improvement in a company. Practical work.

9. Strategic development of manufacturing companies, 8 hours

• Setting strategic goals of manufacturing companies, based on production specifics and market trends. Practical work.

• Creating a business model of the company according to the “Business Model Canvas” methodology.

• Principles and methodology of the “profit 2x2” strategy (doubling profits in two years). Practical work.

• Using the TOC “conflict cloud” methodology to eliminate internal conflicts and contradictions. Practical work.

• Using the TOC “Future Reality Tree” methodology to develop a change implementation plan. Practical work.