Production Management Certification Training Course Outline

Section One: Overview  

Module One: How Technology and New Software Are Changing Manufacturing 

  • Industry 4.0 
    • Key Components of Industry 4.0 
    • Key Principles of Industry 4.0 
    • Benefits of Industry 4.0 
    • Challenges 
    • Industry 4.0 Implementation 
  • The Smart Factory 
    • Key Characteristics and Features of a Smart Factory 
    • The Smart Factory @ Wichita by Deloitte 
  • Cloud Computing 
    • Key Service Models In Cloud Computing 
  • The Internet of Things (IoT)
    • Key Benefits of IoT in Manufacturing 
    • How Does It Work? 
    • Applications within the Supply Chain 
  • Enterprise Resource Planning (ERP), Material Requirements Planning (MRP I), and Manufacturing Resource Planning (MRP II)
    • What is ERP? 
    • Material Requirements Planning (MRP I)
    • Manufacturing Resource Planning (MRP II)
  • Robotics 
    • Industrial Robots 
    • Collaborative Robots (Cobots)
    • General Robot Types 
  • 3D Printing 
    • How Does 3D Printing Work? 
    • Most Common 3D Technologies
    • 3D Printing Materials 
    • Applications of 3D Printing in Manufacturing 
    • Advantages of 3D Printing for Manufacturing 
    • Costs 
    • 4D Printing 
    • Key Features of 4D Printing 
    • How It Works 
  • Blockchain or Distributed Ledger Technology (DLT)
    • Key Features of a Blockchain 
    • Applications of Blockchain for Manufacturing 
    • Setting Up a Blockchain for a Company’s Supply Chain 
  • Predictive Analytics 
    • Key Components and Characteristics of Predictive Analytics 
    • Applications of Predictive Analytics (PA) In Manufacturing 
    • Five Compelling Reasons Predictive Analytics Is a Game Changer for Manufacturers 
  • Artificial Intelligence (AI)
    • Two Broad Categories of AI
    • Key Concepts and Approaches in AI
    • AI Applications in Manufacturing 
  • Virtual/Augmented Reality 
    • Virtual Reality (VR)
    • Augmented Reality (AR)
    • Mixed Reality (MR)
  • Advanced Materials 
  • Nanotechnology 
    • Key Aspects of Nanotechnology 
    • Emerging Fields within Nanotechnology 
    • Applications of Nanotechnology In Manufacturing 
  • Guide to Avoiding Deceptive Practices in Manufacturing Software Purchases 

Module Two: Laying the Foundation for Success 

  • Manufacturing Trade Associations 
    • Benefits of Joining a Trade Association 
    • Potential Downsides to Consider
    • List of Trade Associations for Manufacturers 
    • Other Notable Manufacturing Sectors 
  • Mission Statement
    • Company Mission Statement and Its Purpose 
    • Creating a Meaningful Company Mission Statement
  • Planning and Control
  • Customer Influence in the Manufacturing Process 
  • Process Categories 
  • Order Qualifiers and Winners 
  • Market Issues 
  • Economic Indicators 
  • Process Analysis and Information Flows 
    • Process Mapping and Analysis 
    • Advantages of Process Mapping 
    • Types of Process Mapping Charts 
    • Process Mapping/Flowcharting 

Module Three: Sales and Operations Planning (S&OP)

  • Purpose 
  • Primary Source for Planning 
  • Primary Objectives 
  • Consensus Meeting 
  • General Design 
  • Balancing Resources 
    • Nontraditional Sources of Workers in Manufacturing 
  • Issues to Consider
  • Development of the Plan 

Section Two: Leadership 

Module One: Getting Started 

Module Two: The Evolution of Leadership 

  • Defining Leadership 
  • Characteristics of a Leader
  • Leadership Principles 
  • An Introduction to Kouzes and Posner
    • Model the Way 
    • Inspire a Shared Vision 
    • Challenge the Process 
    • Enable Others to Act
    • Encourage the Heart
  • A Personal Inventory 
  • Servant Leadership 
  • Creating an Action Plan 

Module Three: Situational Leadership 

  • Situational Leadership: Telling 
  • Situational Leadership: Selling 
  • Situational Leadership: Participating 
  • Situational Leadership: Delegating 

Module Four: Lead through Team Building 

  • What Is the Purpose of a Team? 
  • What Are the Characteristics of High-Performance Teams? 
  • Why Is It Important to Build a Strong Team? 
  • What is Team Leadership? 
  • Accountability as a Team Leader 
  • Understanding Span of Control: Balancing Efficiency and Oversight 
    • What is Span of Control?  
    • The Role of Span of Control in Manufacturing  
    • Factors Influencing the Ideal Span of Control 
    • Best Practices for Managing Span of Control 
    • General Recommended Span of Control Numbers  
    • Factors to Consider When Adjusting Span of Control 
    • Recommended Span of Control Numbers for Manufacturing Positions  
  • Standard Operating Procedure (SOP) 
    • 10 Guidelines for Developing Effective Standard Operating Procedures (SOPs) for Manufacturing 
  • Performance Indicators (PI)
    • Annual Performance Reviews 
    • Key Performance Indicators (KPIs)
    • What KPIs Should Indicate 
    • Overall Equipment Effectiveness (OEE)

Module Five: Lead by Example 

  • Determining Your Way 
  • Being an Inspirational Role Model
  • Influencing Others’ Perspectives 
    • Basic Influencing Skills 
    • The Art of Persuasion 
    • The Principles of Influence 
  • Creating an Impact
  • Consistency 
    • Emphasize the Value of Learning 
  • Remove Toxic People 
    • Building a Business Case to Remove a Toxic Employee 

Module Six: Lead by Communicating with Your Team  

  • Communicate the Company’s Vision 
  • Choosing Your Vision 
    • Communicating Your Vision 
    • Identifying the Benefit for Others 
  • Encourage Clear Communication 
    • Communicate in Brief
    • Open Lines of Communication 
    • Establish Positive Feedback as a Foundation of the Team’s Culture 
  • Conflict Resolution 

Module Seven: Lead by Establishing Trust, Respect, and Encouraging Growth 

  • Encouraging Growth in Others 
  • The Critical Role of Leadership Training Before Promotion 
  • Creating Mutual Respect
  • The Importance of Trust
  • Good Teams Make Mistakes. Great Leaders Allow Them To 
    • Manufacturing Mistakes that Lead to Groundbreaking Innovations 

Module Eight: Lead by Motivating Your Team  

  • Motivation Theories 
    • Herzberg’s Theory of Motivation 
    • Factors that Contribute to Dissatisfaction 
    • Actions to Address Excessive Turnover
    • Theory of Expectancy 
    • Autonomy, Mastery, Purpose 
  • Intrinsic and Extrinsic Motivation 
    • What is Intrinsic Motivation? 
    • Three Key Essentials for a Motivated Workforce 
    • What Is Extrinsic Motivation? 
  • Team Incentive Allowances 
    • Why Provide Incentive Allowances for Team Benefit? 
    • Suggested Uses for the Incentive Allowance (Team-Focused)
    • Implementation Considerations 
  • Personality’s Role in Motivation 
    • Identifying Your Personality Type 
    • Identifying Others’ Personality Type 
    • Motivators by Personality Type 
  • A Personal Toolbox 
    • Building Your Motivational Plan 
    • Encouraging Growth and Development
    • Getting Others to See the Glass Half-Full
    • The Key Factors 
  • Addressing Specific Morale Issues 
    • Dealing with Individual Morale Problems 
    • Addressing Team Morale 

Module Nine: Lead by Setting SMART Goals 

  • Norms and Standards 
  • Introducing the GROW Model
    • Goals in the Context of GROW   
  • Setting SMART Goals

1. Specific Goals

2. Measurable Goals

3. Attainable Goals

4. Realistic Goals

5. Timely Goals

6. Monitoring Results

  • Goals and Motivation 
    • Establishing Performance Goals 
    • Strategic Planning 
    • Job Analysis 
  • Evaluating and Adapting 
    • The Three P’s 
    • Ask for Their Input

Module Ten: Employee Assistance Program (EAP)

  • The Program  
  • Getting Employees Help 
  • Leveraging a Company’s Buying Power
  • Employee Savings Program  
  • Starting an EAP Program  

Section Three: Creating Operational Excellence 

Module One: Building an Intrinsically Motivated Company 

  • Hiring for an Intrinsically Motivated Company 
    • Questions to Ask to Determine If Someone Is Intrinsically Motivated 
    • Hiring Practices 
  • Promotion Policies 
  • How Does the Company Benefit? 
  • Going Forward 

Module Two: Production Planning, Scheduling, and Control

  • Production Roles and Duties 
    • Production Manager
    • Production Planner
    • Maintenance Planner
    • Production Scheduler
    • Production Supervisor
    • Duties of All Departments 
  • Production Activity Control (PAC) Planning and Scheduling Best Practices 
    • Why is PAC Necessary? 
    • Separate Department
    • To Get the Department Out of a Reactive Mode, the Planner Must Focus on Future Work 
    • The Job Plan 
    • Kitting and Staging 
    • Planner’s Daily Timeline 
    • Feedback 

Module Three: Inventory Management

  • Maintaining Accurate Inventory Records 
  • Basic Concepts 
  • Costs of Inventory 
  • Costs of Not Having Inventory 
  • Inventory Management Metrics 
    • Economic Order Quantity (EOQ)
    • Reorder Point or Minimum Quantity 
    • Safety Stocks 
    • Inventory Turnover

Module Four: Asset Tracking 

  • Stock Keeping Unit (SKU)
  • Automatic Identification and Data Capture (AIDC)
    • Barcodes and QR Codes 
    • Reading Barcodes 
    • Where do I obtain barcode numbers for our products? 
  • Radio Frequency Identification (RFID)
  • Voice Recognition 
  • Barcode Readers 
    • What is a barcode reader? 
    • How do barcode readers work? 
    • Technical Standards 
    • Barcode Readers 
    • Types of Barcode Readers Used in Manufacturing Operations 
    • How to Select a Barcode Reader

Module Five: Just-In-Time and Lean Production 

  • Actions to Address Uncertainties and Challenges Within a Production System

  2. What is Kanban?

  8. Kaizen Methodology

  9. Heijunka

10. Andon Board

11. Single Minute Exchange of Die

    • The Seven Principles of Total Quality Management (TQM)
    • Total Productive Maintenance (TPM)
      • Total Productive Maintenance (TPM): The Eight Pillars 

Module Six: Theory of Constraints 

  • The TOC Five-Step Process 
  • Root Cause Analysis 
    • When to Perform a Root Cause Analysis 
    • The  3Rs of Root Cause Analysis 
    • How to Do a Root Cause Analysis 
    • Forms of Root Cause Analysis 

Conclusion: Challenging the Process 

  • Why Is Change So Difficult?

1. Change

2. Commitment and Consistency

3. The College Myth

  • Think Outside the Box 
  • Developing Your Inner Innovator
  • Seeing Room for Improvement
  • Lobbying for Change 
  • Reverse Mentoring 
  • Convincing Management Change Is Needed 
  • How Do You Convince Someone Committed to Consider Other Options?