This curriculum spans the technical and organisational challenges of integrating digital systems into lean and continuous improvement workflows, comparable in scope to a multi-site operational technology rollout or an enterprise-wide continuous improvement platform implementation.
Module 1: Aligning Technology with Lean Principles
- Selecting real-time data collection tools that minimize operator burden without compromising process visibility
- Integrating shop floor IoT sensors with existing MES systems while maintaining data integrity during downtime
- Designing user interfaces for Andon systems that reduce cognitive load during escalation events
- Deciding between centralized versus decentralized data storage for value stream mapping initiatives
- Implementing pull-based material replenishment systems using RFID and Kanban software integrations
- Validating accuracy of cycle time measurements collected through automated time-stamping versus manual logs
Module 2: Data Infrastructure for Continuous Improvement
- Establishing data governance policies for operational data ownership across plant and corporate IT teams
- Choosing between cloud-based versus on-premise historian systems for long-term process trend analysis
- Normalizing data formats from legacy SCADA systems to enable cross-facility benchmarking
- Deploying edge computing devices to preprocess high-frequency sensor data before cloud transmission
- Configuring role-based access controls for performance dashboards across union, supervisory, and executive levels
- Designing data retention schedules that balance regulatory compliance with storage cost constraints
Module 3: Digital Tools for Process Mapping and Value Stream Analysis
- Selecting VSM software that supports dynamic updates based on live production data feeds
- Automating takt time calculations using actual output and demand data from ERP systems
- Integrating GPS and RFID tracking to validate physical flow assumptions in complex logistics networks
- Building interactive digital value stream maps accessible to cross-functional teams via mobile devices
- Version-controlling process maps to track improvement iterations and audit change rationale
- Mapping non-value-added activities in administrative processes using workflow automation logs
Module 4: Statistical Process Control and Six Sigma Technology Integration
- Configuring automated SPC rules in manufacturing execution systems to reduce false alarm rates
- Integrating Minitab analysis workflows with real-time control charts in production environments
- Deploying automated gage R&R studies using connected measurement devices and calibration databases
- Embedding Six Sigma project templates into PLM systems to enforce DMAIC phase gate reviews
- Synchronizing FMEA updates with process deviation alerts from quality management software
- Using machine learning models to detect multivariate process shifts before SPC rule violations occur
Module 5: Automation and Error-Proofing (Poka-Yoke) Systems
- Specifying vision system tolerances for automated defect detection in high-mix production lines
- Designing interlocks between torque tools and MES to prevent assembly sequence deviations
- Implementing barcode verification systems at kitting stations to prevent component substitution
- Calibrating ultrasonic sensors in poka-yoke jigs to account for environmental temperature drift
- Integrating RFID-enabled tool cribs with work instruction systems to enforce tooling requirements
- Documenting and testing fail-safe behaviors in automated systems during power or network outages
Module 6: Performance Monitoring and Continuous Feedback Loops
- Designing OEE dashboards that reconcile data from machine PLCs, labor tracking, and quality inspection systems
- Automating daily stand-up reports using filtered alerts from production monitoring platforms
- Configuring predictive maintenance triggers based on vibration and thermal sensor trends
- Linking kaizen board software to ERP downtime codes for root cause trend analysis
- Validating accuracy of automated scrap tracking against physical inventory reconciliation
- Standardizing KPI definitions across global facilities to enable meaningful benchmarking
Module 7: Change Management and Technology Adoption in CI Programs
- Phasing pilot deployments of new CI software to minimize disruption during peak production cycles
- Developing offline data capture capabilities for teams operating in low-connectivity areas
- Conducting usability testing of mobile CI apps with frontline workers before enterprise rollout
- Integrating improvement idea submission systems with existing HR recognition processes
- Training super-users to troubleshoot common connectivity and data sync issues without IT escalation
- Aligning software update schedules with plant maintenance shutdowns to reduce operational impact
Module 8: Scaling and Sustaining Technology-Enabled Improvement Initiatives
- Creating centralized CI data lakes that aggregate project outcomes from multiple plants
- Standardizing API contracts between CI platforms and enterprise systems to reduce integration debt
- Conducting technical debt assessments for custom CI automation scripts and macros
- Establishing cross-functional governance boards to prioritize CI technology investments
- Measuring adoption rates of digital tools using login frequency and feature utilization metrics
- Developing decommissioning plans for legacy CI systems to avoid parallel run confusion
