OACADEMY - oConsulting...Preparation: Laptop with Minitab Certification: Certificate of attendance...

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Capability Building 2020

OPEX Trainings and Workshops

OACADEMY

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“A company can seize

extra-ordinary opportunities

only if it is very good at the

ordinary operations.”

Marcel Telles


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ABOUT OIt’s O for Operations. We are a team of dedicated consultants with long

hands-on experience in Operations and a lot of passion for improving processes, systems and organizations. It’s an old truth that it’s the people who are key to a factory’s success. And, being experts for capability building, we know that there is more to developing people than teaching methods.

What is Operational Excellence? Operational Excellence enables

organizations to improve quality while significantly shortening throughput times, reducing production costs and increasing output without additional investment. Working on process improvement is a key to sustain motivation.

O ACADEMYFrom Practitioners for Practitioners. Our trainings and workshops are

inspired by our daily work with our clients. Combining coaching and practice, they are designed to enable effective project work, leadership behavior and fast results. Together with you, we develop ideas to achieve wide-reaching impact in your organization. Our OPEX Belt Trainings address all levels of competence building for process improvement experts, whereas the focus of our Training Workshops lies on experienced guidance through current business challenges.

OPEX BELTS TRAINING WORKSHOPS

Together, we develop your capabilities to

drive process improvements

Together, we tackle your challenges while

developing capabilities


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Our Clients

It is our passion to leverage the know-how of your people with our experience, achieving sustainable results together. We work extensively in the Life Sciences (Pharmaceutical and Medical Device production) and have significant experience across a broad range of industries.

We are proud that oConsulting, former Valeocon, has a strong reputation as

provider of Operational Excellence certifications by these companies.

“We found a partner in oConsulting that has been able to give advice on many subjects, leading to a long term valued relationship.”

“Really appreciate: Instructor’s effort to implement

our suggestions & requirements.”

“Great ability to explain complex matter understandably.”

“The consultant was a very good presenter and teacher.

He has great ability to present information in a way that is

easy to understand and remember.”

“Creative learning techniques

very well prepared.”


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OPEX BELTS

We recommend to register two months before the first day of trainingWe also offer all courses in-houseGroup discounts for multiple participants in the same session

Mon Tue Wed Thu Fri

Apr CW 14

May CW 19

Jun CW 23

Jul CW 29

Aug CW 34

Sep CW 38

CW 41

CW 43Oct

Green Belt - Part 2 (Sep 15-17)

Master Black Belt (Oct 12-16)

Green Belt - Part 3 (Oct 20-22)

GB refresher (Jul 14-15) BB refresher (Jul 16-17)

2020

Black Belt - Part 1 (Mar 31 - Apr 2)

Black Belt - Part 2 (May 4-7)

Black Belt - Part 3 (Jun 2-4)

Green Belt - Part 1 (Aug 18-21)

Do you love to drive improvement? Become a certified process improvement expert and change your workplace for the better.

To create the best possible training experience tailored to the needs of your organization, each of our programs starts with understanding your challenges, demands and goals. The special feature in all our trainings: immediate application of the achieved skills to a process improvement project addressing a significant business need for your company. We provide advice on project selection and individual coaching during project progression. Upon successful completion of your improvement project, you will obtain our well-recognized certification as OPEX / Lean Six Sigma Belt.

Our OPEX Belts:

Yellow Belt

Green Belt

Black Belt Bridge

Master Black Belt

GB/ BB refresher


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Training Program (1 day)

Introduction and Expectations

Simulation Round 1

Introduction to OPEX

Problem Definition

High level process mapping

Voice-of-Customer & CTQ

Pareto Principle

Value-Added Flow-Analysis

Simulation Round 2

Depending on your improvement program, audience and available time, this training can be enhanced to two or three days by adding more of the basic tools. For longer trainings the simulation rounds will be distributed over the days to maintain a high level of engagement.

Yellow Belt

Interactive and fun Pizza delivery simulation to make the concepts & tools tangible and to increase the motivation in the organization

For whom: Everyone to be involved in process improvement projects, typically subject-matter-experts, managers, process owners and team members

Preparation: None

Certification: White Belt certification for participation in the training, Yellow Belt upon documented improvement of a process

You would like to increase your service quality and improve your operational processes? Enable everyone in your organization to support a process improvement initiative and raise awareness for Operational Excellence. Yellow Belt trainings provide the perfect opportunity to reach many people and communicate Lean Six Sigma basics to work in a strong customer- & result-oriented way.

Training Outcome✓ Confidence to explain the idea of Operational Excellence and Lean Six Sigma to

colleagues✓ Ability to contribute to a process-improvement project

1-3 daysOn request

On your site

Max. 16 participants

On request

Key Features


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Key Features

Part 1 (3 days)

Basics: DMAIC, problem definition, customer focus, project management, statistical thinking

Quick-Win techniques: 7 Wastes, 5S

Data-based process analysis: Process mapping, Lean metrics, discrete measurement system analysis, data collection, qualitative root cause analysis

Data-based process monitoring & validation: Control Charts, process capability calculations

Part 2 (4 days)

Quantitative root cause analysis: Basic hypothesis tests, simple linear regression

Process improvement: Dogma Busting & Blue Sky, Standard Work, Poka-Yoke, Visual Management, Flow & Pull

Part 3 (3 days)

Sustainable implementation: Mitigating risks, agile implementation principles, PDCA for continuous improvement

From project to daily business: Process-check-on-site, statistical process control, roles and responsibilities, project close-out

Training closure: Final recap, exam and take-aways

Green Belt

Learn through direct practical application in interactive simulations and exercises

Measurable business results from leading a Green Belt improvement project

Receive support with project selection and coaching throughout training

For whom: Everyone with a passion to improve processes

Preparation: Process requiring significant improvement, laptop with Minitab

Certification: Certificate of attendance after completion of the exam, Green Belt certification after successfully completed GB-project

You would like to execute a process improvement project with Lean Six Sigma tools? Achieving significant performance improvements is crucial for the future competitiveness while requiring time, energy and communication. Green Belts are experts in solving process problems with the efficiently structured, fact-based project approach DMAIC, focusing on sustainability.

Training Outcome✓ The numerous skills needed to lead DMAIC projects

10 days• Aug 18-21, 2020• Sep 15-17, 2020• Oct 20-22, 2020

HamburgMax. 12 participants

€ 5,700per person


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As a Green Belt you have already experienced the power of Operational Excellence during previous process improvement projects and training. Take this to the next level and tackle higher value projects: multiple stakeholders, difficult data analysis, more complexity! Learning the advanced tools and roadmaps not just helps you to succeed, but also to coach Yellow and Green Belts.

Training Outcome

✓ Strengthened expertise and repertoire✓ Ability to select most efficient roadmap / tools for each scenario in operations

For whom: Part- and full-time improvement experts who lead complex projects and coach other improvement project leaders

Preparation: Green Belt certificate, complex improvement project, laptop with Minitab

Certification: Certificate of attendance after completion of the exam, Black Belt certification after successfully completed BB-project

Part 1 (3 days)

Project selection: 1-2-3 Model, Value Stream Mapping, Voice-of-Customer and demand analysis, OPEX business cases

Data-based process analysis: Additional distributions, transformation, continuous measurement system analysis, gage linearity, baseline analysis for non-normal data

Part 2 (4 days)

Quantitative root cause analysis: Power & sample size, advanced hypothesis tests, multiple non-linear & logistic regression

Finding best solutions: Creativity techniques and facilitation, Design of Experiments (DOE), Monte Carlo simulations

Part 3 (3 days)

Leadership & Change: Setting up ShopfloorManagement for continuous improvement

Data-based process control: Sustain change with monitoring for all types of data

Specific roadmaps: IDOV/DFSS, Kaizen, RCA, SMED, OEE, Lean Lab, Lean Transformation

Training closure: Final recap, exam and take-aways

Black Belt Bridge

Strengthen your leadership and facilitation through teachbacks

Measurable business results from leading a Black Belt improvement project

Receive support with project selection and coaching throughout project lead

10 days• Mar 31-Apr 2, 2020• May 4-7, 2020• Jun 2-4, 2020


€ 6,500/ € 4,300*per person

* If booked with GB

Key Features


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Key Features

Day 1 – Leadership SkillsRole of the MBB

Coaching project sponsors

Facilitating site leadership decisions

Day 2 – Advanced StatisticsMultiple curvi-linear regression

Recap & Advanced DOE

Day 3 – Opportunity IdentificationLean Management Systems

Financials for OPEX Leaders

Day 4 – Setting up for SuccessStrategy Deployment

Portfolio Management

Specific topics of interest

MBB Exam Preparation

Day 5 – Exam (4 hours)100 Multiple Choice questions on OPEX

10 open questions on approaching different project situations

3 case studies using advanced statistics in Minitab to conclude practical advice

Follow up Coaching (4 hours)Session 1: Exam review

Sessions 2-4 per individual choice

Master Black Belt

Final agenda will be tailored to the needs of this small expert group

Ample networking and exchange built in to allow benefitting from the deep expertise of fellow participants

For whom: Site- & Global OPEX leaders who want to become or improve as MBBs

Preparation: Laptop with Minitab, Black Belt certificate, portfolio of led and coached OPEX projects

Certification: MBB certification requires successfully completed projects solving complex problem, 10+ coached OPEX projects, co-delivery of BB training and having advanced OPEX in one’s company

A Black Belt knows how to manage cross-functional projects. As Master Black Belt, there is a stronger focus on leading employees, business processes and functions. As drivers of OPEX Deployments and working directly with site management, Master Black Belts have both: a solid foundation in advanced methods as well as the ability to drive change on the highest level.

Training Outcome✓ Highest level of OPEX expertise✓ Prepared for leading OPEX across a business

5 daysOct 12-16, 2020


€ 4,000 per person


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You were certified many years ago and, maybe after a pause in OPEX work, you would like to refresh your knowledge? Or recap the tools before pursuing the next level of certification? Learning about the latest additions to the OPEX toolkit and exchange with other experienced practitioners sounds like a good idea? Then join one or both of our refreshers – Either way the training will be tailored to address your most pressing questions.

Training Outcome✓ Refreshed and deepened understanding of the most relevant tools

Part 1 (2 days) – Green Belt Refresher

Basics: DMAIC, project management, customer focus

Data-based process monitoring & validation: Basic statistics, selecting metrics, Control Charts, process capability calculations

Selected OPEX tools: Determined by participants’ needs, typically includes Lean metrics, value added analysis and hypothesis testing

Part 2 (2 days) – Black Belt Refresher

Basics: Various OPEX roadmaps, 1-2-3 Model

Leadership: Engaging stakeholder, training, coaching, facilitating

Selected OPEX tools: Determined by participants’ needs, typically including advanced data analysis tools

Green & Black Belt Refresher

Refreshed tools will include the ones most relevant for you

Work on your most critical OPEX problems during the training

Exchange with experienced practitioners

Individual coaching opportunity

For whom: Green & Black Belts

Preparation: Laptop with Minitab

Certification: Certificate of attendance displaying list of topics

2+2 days• Jul 14-15, 2020• Jul 16-17, 2020


€ 1,400 / € 2,500*per person

Key Features

* For both refreshers


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TRAINING

WORKSHOPS

How about a training & workshop at your site, addressing specifically the real-life cases of your business?

As dedicated practitioners we like to roll up our sleeves and become part of your team to work on improvements. Our training workshops are tailored towards meeting the needs of a specific group or organization. They are interactive trainings with a stronger focus on delivering results while ensuring the appropriate tools are selected and learning takes place by action and reflection. Coaching and feedback are the most important elements and enable your people to master new challenges.

Our Training Workshops:

Toyota Kata

Lean Implementation Expert

Train-the-Trainer

Shopfloor Problem Solving

Root Cause Investigation

Statistics for APQR / CPV [Life Sciences]

Design Excellence


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Workshop Program

Get an overview of our suggested approach to implement Toyota Kata, how to use the needed templates and practice during the training

Background: What is Toyota Kata?

Improvement and coaching Kata

Kata training in the Classroom KiC”

6 steps after training

Kata cascade to break down challenges

Schedule for coaching Kata cycles

Kata approach check-up

Work with typical Toyota Kata tools like coaching plan, 5 questions & 4 steps, Kata board

Practice Kata coaching techniques

Move to action: Where to implement Toyota Kata and implementation plan

Toyota Kata Awareness

Effectively strengthen your leadership skills through experimenting with methodologies, role plays and feedback

Key success factors to implement Toyota Kata: a strong coach-trainer relationship and practices within the real shopfloor environment

For whom: For leaders in all environments

Preparation: Bring your own challenge

Certification: Participation

Toyota Kata is a leadership approach and style. It helps to turn around the dynamics of an organization and generates improvement bottom-up while setting challenges top-down. It prevents enthusiastic Lean leaders from the typical phenomenon of generating a lot of initiatives in production without prioritizing them. Toyota Kata applied in the right way can be very motivating and inspiring.

Workshop Outcome✓ Understanding the idea of Toyota Kata and its benefits for your organization✓ First experience and find leadership inspiration by applying Toyota Kata

1 dayOn request

On yoursite

4 – 8 participants

€ 2,500

Key Features


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Key Features

Scoping (0.5-1 days, free of charge)

Definition of business problems to solvePreparation activities

Session 1 (2 days)

Training: Setting up projects and Kaizen workshops, facilitation skills, basic Lean tools like 5S, 7 Types of Waste and PDCAPreparation: Schedule meetings for implementation support with coach

Individual project support (1 day per project)

Hands-on support by consultant on your site

Session 2 (3 days)

Deeper into scoping and executing the projects, Lean metrics, OEE, Gemba, process mapping, Value Stream analysis, standard work and SMED

Individual project support (1 day per project)

Hands-on support by consultant on your site

Session 3 (2 days)

Deep dive into methods to support leaders and make success sustainable like Performance Management, 1-2-3, problem solving, Flow, Pull and Kanban

Lean Implementation Expert

ROI of typically 5:1 within one year

Great addition to Lean transformation programs

Selection of tools specifically tailored to you

For whom: Those dedicated to driving improvement and with a career plan to professionally support their organization with Lean

Preparation: Bring a challenge or a project

Certification: Certification as Lean Implementation Expert for successful implementation

Implementing Lean and supporting Lean transformations requires project leaders with versatile skills: It’s about enthusing and convincing people on all levels of the organization, it’s about managing projects and change. The ability to build on right methods and approaches determines success.

Workshop Outcome✓ Experience of the key Lean methods✓ Successfully solved business challenge✓ Capabilities for repeated success developed on site

7 days training +2 days support per participantOn request

On your site

3 – 5 participants

€ 7,500per person


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Workshop Program (2 days)

Teach-backs with lots of feedback are built in throughout the day

Purpose of Lean trainings

Defining learning objectives

Preparing a training

Structuring a module to be interactive

Generating the Lean experience

Typical Tools & Methods

We recommend to prepare one of these topics:

Waste and Value

5S

Standard Work

Yellow Belt simulation

Train-the-Trainer

Very small groups for the best training experience

After receiving valuable input you will have the opportunity to practice your trainer skills and receive qualified feedback

For whom: Future inhouse trainers

Preparation: Bring a training module you want to facilitate


Implementing Lean requires to train people on all levels of the hierarchy. Thereby, the quality of the training itself represents a first success factor. Trainings need to be adapted regarding the deepness of theory. They should be exciting, practical and fun to ensure a lasting learning experience. This training workshop establishes the capabilities to get there.

Workshop Outcome✓ Developed capabilities to run excellent in-house trainings on Lean topics

2 daysOn request

On your site

Max. 4 participants

€ 5,000per workshop

Key Features


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Key Features

Workshop Program (2 days)

Discover the power of systematic problem solving

Tools to identify root causes

Exercise root cause identification and experience the effect

Implement the solution and make it sustainable

Typical Tools & Methods

Problem definition

PDCA

Fishbone (Ishikawa)

5W1H

Action Plan

Visualization

A3

Shopfloor Problem Solving

Fun and revealing case everyone can relate to

Highly interactive through intensive group-work and real-time problem solving

For whom: Everyone to be involved in systematic problem solving, typically operators, technicians, team leadersfrom production, engineering, assembly

Preparation: Select real shopfloorproblems to be tackled during the training


On the shopfloor, most people understand a goal once they have started to work on it. Thus, problem solving is at the core of motivating people to achieve goals. The training will help to greatly develop self-confidence and motivation. It will also generate ideas for improvements and show when to rely more on systematic problem solving.

Workshop Outcome✓ Capabilities to solve real problems quickly and sustainably✓ Implement a culture of reviewing root causes instead of jumping to solutions

2 daysOn request

On your site

Max. 8 participants



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Day 1

Introduction and expectations

Overview of the investigation

Lessons Learned from deviations rRCIdiscovery case

Root Cause Investigation thought process template

Problem Statement

Is/Is Not & timeline

Distinctions/changes

Fishbone/ 5 Why’s

Contradiction Matrix

Confirm true cause

Day 2

Presentation of practice case

Solving the case in groups

Solving cases from your site

Closure, evaluation next steps

Root Cause Investigation

Experienced support during investigation of current and open cases from your site

Highly interactive through intensive group-work and real-time deviation investigation

Specific to industries where addressing a deviation must also be documented, such as Automotive, Aerospace or Life Sciences

For whom: Leaders of deviation/ root cause investigations, Quality, QA

Preparation: Bring an open investigation case with related documents ready

Certification: Certification of participation and closing deviation

Especially in regulated environments, it is important to efficiently identify and document the root causes of deviations. At the same time, truly understanding the root cause provides an opportunity to stabilize and improve your processes. Not being able to release a batch due to an open deviation could be an expensive, nonetheless, often avoidable issue.

Workshop Outcome✓ Systematic and thorough identification of root causes of complicated deviations✓ Increase efficiency and sustainability of closing deviations

2 daysOn request

On your site



Key Features


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Key Features

Day 1 – Basic Statistics

Types of data

Types of distributions

Sample size confidence

Measurement systems

Day 2 – Process Analysis

Process stability

Process capability

Capability Sixpack

Day 3 – Cause-Effect Analysis

Hypothesis testing

Simple Linear Regression

You will also learn to effectively visualize statistical conclusions and summaries, allowing for efficiency in reading reports and clarity for decision-making.

Statistics for APQR / CPV

Case studies from the Life Sciences

Statistics become easy to work with and even fun!

For whom: Everyone preparing or supporting product reports

Preparation: Laptop with MINITAB, process data must be sent to the trainer before the course (can be anonymized)

Certification: Certification of participating in training and about tools learned

The expectations of health authorities regarding the use of statistics in Annual Product Reviews, Product Quality Reviews and Continued/Ongoing Process Verification (APR / PQR / CPV / OPV) have increased. Historically it was enough to be “inside the spec limits”, today producers are expected to explain their product’s variation using Control Charts and Ppk.

Workshop Outcome✓ Application of statistical principles to assess product behavior and performance✓ Working more efficiently by only doing the relevant calculations

3 daysOn request

On yoursite




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Workshop Program (1 day)

Design Excellence background

Design Excellence within a typical new product introduction process

Design Excellence simulation

Design Excellence tools like requirements identification and prioritization, Design Excellence Scorecard, product and process risk analysis, basics on process capability and control

Design Excellence Awareness

Use of a fun Lego simulation to illustrate Design Excellence concept and tools

For whom: Line Management affected by development projects from Marketing, R&D, Operations, Life Cycle team leaders, Project leaders and R&D project team members

Preparation: None


Design Excellence is the concept of developing new products in a way to balance quality (what does the customer want?) and manufacturability –(what can we produce efficiently and effectively?). To meet this balance, it is important to manage the design flow in both directions and simultaneously, consider requirement management and robust design.

Workshop Outcome✓ Awareness of Design Excellence and its implications for your role✓ Understanding the flow of the Design Excellence tools and how they work

together, especially in the context of the Design Control process

1 dayOn request

On yoursite



Key Features


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“Perfection is achieved, not when

there is nothing more to add, but

when there is nothing left to take

away.”

Antoine de Saint-Exupéry


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Hamburg Office

Winterstr. 422765 HamburgGermany

Phone +49 40 18 88 86 [email protected]

www.linkedin.com/company/oconsulting-gmbh

www.oconsulting.com/academy

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