Writing Better Production Routines

Learn how to:

Define foundation knowledge, Formalise base conditions and visibility of early warning/problem prevention triggers, Capture tacit knowledge and Systemise front line skill development.

Understand how to:

Establish practical work routines that are easy to do right, difficult to do wrong and easy to learn, Create learning plans with clear competency signposts, Identify and deal with skill gaps.

Be able to:

Develop robust learning plans for target assets, Apply relevant visual management to simplify tasks and reduce human error, Integrate asset care into operator activities as part of the work routine.

• Aims and Objectives of Operations/Operating Procedures
• Understanding Normal Conditions: Setting basic conditions, Recognising early warning signals, Making them visible
• Designing Standard Operator Procedures: Standardising work routines for Start up, Steady state, Close down/Clean out, Integrating routine asset care
• Understanding human error and problem prevention: Recognising complexity, Centrelining
• Writing Standard Operating Procedures: The building blocks, Terminology, Key term definition, Standardising work instructions, Visual indicators, Setting condition standards, Validating draft and final versions.
• Learning to learn: Foundation knowledge, Process cycles, Dealing with common problems, Knowing where to stop, Adult learning, Setting out learning steps, Practical activities, Competency assessment
• Continuous Improvement: Assessing waste and added value, Refining working methods and saving time,
• Improving operability, Preventing recurring problems
• Action Planning; Priorities for action, 90 day plan development
• Review of the workshop and close

The workshop content is designed to help those challenged with formalising, refining and standardising working methods that are easy to do right, difficult to do wrong and simple to learn. The approach is applicable to Lean, TPM, Six Sigma improvement toolsets.

It is also relevant for managers and change agents who want engage workforce with continuous improvement of working methods. The workshop approach combines theory, case studies and hands on practical application including the use of a simple review framework to build on current SOP strengths and address areas of weakness.

The workshop will be led by Colin Sanders.

Colin's career spans supervisory and senior operations management roles. As a consultant Colin has supported improvement and change management programmes as a project manager, advisor, and facilitator. His consultancy experience includes the application of business process reengineering and implementation of performance measurement to raise operational work standards and support the delivery of business improvement goals.

Industry experience includes food manufacturing and processing, engineering, medical supplies and steel fabrication. This has included working with well respected and award winning companies such as Glanbia, Kepak, Johnson and Johnson and AEA Technology.