Our Programs...

Benchmarking

This program represents a fresh, practical and highly effective way for companies to exploit the benchmarking process. We work with senior management to select a team of operational people, often from different divisions or departments, who are given the task of achieving significant operational economies. We train the team in process measurement, data analysis, project management, team-based problem solving techniques and benchmarking. We guide the team through the early project stages until it has determined "best practices" for recommendation and adoption through each facility. The process can be applied internally within one site, across a number of sites in one company or between 'partnering' companies.

Beyond The Black Hole

(The Principles and Practices of Lean Manufacturing)

The theme of this two-day workshop is service and productivity improvement through Lean Manufacturing. The objective is to present to management and employees a practical and proven roadmap for making sustainable and significant change. We go through the actual process of transforming a (simulated) typical manufacturing company that is constrained by narrow thinking, departmental barriers and complex systems. Step-by-step, we work through a series of techniques designed to radically improve operational performance in production and administration. The improvements are measured and the participants see and experience the outcomes of the changes that they implement in the simulated company. The simulated company starts out with a typical departmentalised structure. The workshop ends with the operations reformed into a customer-focused business unit which meets all customer requirements in a fraction of the time and at a fraction of the cost.

Blitzing The Value Stream

Service, support and administrative efficiencies have always been difficult to measure. Efforts to improve office productivity are usually intra-departmental and ignore the needs of other departments or their impact on the overall efficiency of the business. The end result is often the introduction of new technologies that incorporate the waste, create mountains of paper and add to the problem. In Optim's new Blitzing The Value Stream program, we expose the unnecessary complexity that has evolved within your own administrative processes.

Using simple concepts and tools, the participants progressively redesign your information flow. Non-value adding activities are eliminated, response times are reduced, systems are simplified and visibility is increased.

The outcome of this program is a redesigned workplace where skills and responsibilities are shared and departmental barriers are demolished. But perhaps the biggest benefit it offers is in the genuine opportunity it provides for operational people to take an active part in improving their own productivity and, by doing so, securing their own futures.

Customer Focused Manufacturing

A factory simulation is used to make comparison between traditional manufacturing typified by a functional layout and batch-and-queue production driven by conventional 'push' scheduling, and contemporary customer-focused 'pull' methodology. This program brings together many of the concepts developed in other Optim programs. The participants get to feel the benefits of working in a very flexible company where all the employees are in touch with the customers and where lean manufacturing has reduced costs and response times. In this workshop, the participants get to see how all the main principles finally come together.

5S And The Visual Workplace

This workshop demonstrates the 5S process and facilitates the immediate implementation of 5S principles in the work place. We work with the people over two days to upgrade the orderliness and maintenance standards of their workplaces. The objectives are to achieve a dramatic change in both the appearance and the functionality and to set new and sustainable standards for the future. This program is often the initiation of activities in the workplace for a company which has elected to pursue Lean Thinking.

Key objectives are:

The elimination of unwanted/unused materials and equipment
Efficient storage and control of equipment and stock at the workplace
The implementation of visual controls
The standardisation of 5S practices to maintain the new work place standards.

High Performance People

Teamwork and team responsibilities are topical issues today. However, rarely do we witness successful implementation, usually because of a lack of understanding of important issues. High Performance People provides a path for involvement by explaining the influence of the group on behaviour, motivation, attitudes and discipline, enabling real teamwork to be achieved in a way that is truly participative and mutually beneficial. This program emphasises the differences between empowerment and involvement, explains the changing roles of people in the new organisation and examines the roles of reward and motivation.

Kanban Basics

Kanban is one of the most successful concepts ever devised to control production flow and to manage the elimination of waste. However, good kanban implementations are uncommon because essential issues are misunderstood or overlooked. This Kanban Basic workshop introduces operational people and their leaders to:

the principles of customer focused manufacturing
kanban functions, rules and types
trigger, traffic light and heijunka boards
kanban calculations
kanban rules
kanban implementation

Kanban Masters

The implementers and owners of a kanban system require in-depth knowledge of the procedures for setting up and running a kanban system. This program looks in detail at the various kanban and sequence board types and how they are used. Time is taken to understand how the kanban formula works for different scenarios and the participants learn to use Optim's kanban 'transition' spreadsheet. The implementation sequence is studied. We look how kanban can be used as a continuous improvement tool and we establish the disciplines that make the system work effectively.

Lead-Time Blitz

We consider the key issues underpinning the competitive success of today's business. We find that the important principles are not exclusive to the Kerry Packers of the world but are, in fact, largely common sense.

The workshop takes us inside two competing companies where we are able to make some interesting comparisons. We see through a simulation exactly what it takes to dramatically improve the performance of the worst company to make it World-Class.

Concepts include:

Customer service
Quick response
Value adding vs Cost Adding
Waste elimination
Process linking
Cellular manufacturing
Batch size reduction

Making Serious Change

This one-day program is for Managers in both manufacturing and service sector industries who want to involve their people directly in productivity and service improvement.
The workshop covers:

Recognising the need for change
The critical role of management
Strategies for improvement
Measuring corporate productivity
People involvement
Incentives
Tools for change
Resourcing change

We address the issues of serious and sustainable change in business through a sound framework of proven principles and practical tools. Participants experience the use of simple techniques for process analysis and improvement. They also develop their own plan for application of the principles on return to their firms.

Murdering The Muda

An effective strategy for uniting the workforce is to focus everyone's attention on a common enemy. In this short workshop, the participants are introduced to the concept of operational waste (muda). They get to see how extensive the waste is and what it is costing the business. We measure the waste using Optim's waste audits and we consider how it might be reduced. The objective is to create a culture amongst the workforce that is obsessed by waste and with its elimination.

New Generation Problem Solving

The "New Generation Problem Solving" course combines teambuilding with creative problem solving techniques and statistical analysis. The participants understand the interdependence of the three elements for success. They experience the satisfaction of a total approach to problem solving. Also, they learn that by working together using basic techniques for data collection and effective team interaction, they can achieve results beyond their own expectations.

Topics covered include: personal influences, setting goals, decision making, creative problem solving, data collection and analysis, project management.

At the conclusion of the workshop the attendees are required to plan and manage a real problem-solving project. At the conclusion of the project they are expected to produce a short report and give a presentation to management and colleagues.

This course has produced some stunning results for a number of Optim's clients. These include massive reductions in product loss, resource waste and manufactured cost with significant improvements in culture and morale.

This course has been accredited by the Ai Group as an optional module for the Leadership ll Certificate - a Frontline Management Course.

New Roles For Supervisors

The supervisor's role is changing as companies move down the path of greater autonomy for middle management and supervision. As roles change, many supervisors feel threatened as subordinates become involved in continuous improvement and change. Supervisors are expected to be leaders and facilitators but in many cases do not have the understanding or skills to effectively fulfil the expectations made of them. This program covers essential topics that must be understood by supervisors before they can feel they have a worthwhile role to play in an environment that needs leaders. This program is designed to be run in stages over a three monthly period of time, so allowing each element of the training to be given time for practical application.

Poka-Yoke

(Mistake Proofing)

Poka-Yoke is a process for addressing mistakes and random failures that occur in every workplace in industry, offices, hospitals, shops and government departments. This short workshop teaches the basic concepts behind Poka-Yoke and the reasons why Poka-Yoke is important to industry. Attendees are given the opportunity to analyse their own equipment for Poka-Yoke applications. Projects are then initiated to apply their ideas back in the workplace.

Process Capability & Variability Reduction

Statistics and measurement lectures were designed by academics to blind, baffle and bore their pupils into submission. Yet the old adage says, "You can't control what you don't measure." Optim has made a breakthrough in the teaching of statistical techniques by making the learning process interactive and fun. The participants are introduced to a process out of control. Using a series of measurement techniques to analyse the current performance, to diagnose the causes of failure, to eliminate variability and to bring the outputs under control, they find they can make the process capable.

Service To Please

Exposing your people to the realities of meeting internal and external customer needs is a very effective technique for improving business performance. We show how to identify those needs and how to develop strategies to ensure that customers become increasingly pleased with the service they receive. The module covers: refocussing the company, identifying customers and their needs, internal and external customers, customer/supplier relationships and the principle ideas behind "50,000 Moments of Truth". The theme is: "If you don't have a customer, you don't have a job. So let's figure out who your customers are and what must be done to excite them."

Smart Changeovers

Changeover reduction can provide immediate cost and productivity benefits, often for only a small investment. Optim's Smart Changeovers program is by far the most popular one of its kind in Australia, having been attended by over 1000 people and 300 companies in the last two years in Australia, New Zealand and North America. The emphasis is on teamwork and creativity in devising low cost solutions. The program can be run over two days on your site and is designed for operators, maintenance fitters and their leaders.

This course has been accredited by the Ai Group as an optional module for the Leadership ll Certificate - a Frontline Management Course.

Smart Changeovers Blitz

Optim's Smart Changeovers Blitz process provides a practical team based approach for the systematic reduction of time loss during changeovers, set-ups, start-ups, shut-downs and routine maintenance functions. The concepts are applicable to all areas of a business and are the same as used in the normal two-day Smart Changeovers course. However, this program provides a sharp kick-start to reinvigorate a previous changeover reduction campaign. Extra tools for analysis are taught and, in a highly intense hands-on program, the focus is on one machine. The changes are made and demonstrated during the workshop. Reductions in excess of 50% are targeted and usually achieved before the end of the workshop.

The program encourages the collective effort of operators, support staff, engineers and management to work together to devise low cost, imaginative solutions to traditional problems and implement them immediately. The whole process takes two days and must be run on site.

Statistical Process Control

This two-day workshop gives attendees a deeper understanding of the fundamentals of statistical process control and how to use statistical tools to improve control over their processes. The attendees learn the fundamentals of SPC through a series of creative and interactive exercises and activities. The course starts at the basics of probability and variability then progresses through histograms, control charts and process capability. The use of SPC software and FMEA analysis is also included in the second day. At the completion of the course attendees are expected to carry out an SPC project.

This course is generally tailored to suit the level of knowledge of the attendees.

This course has been accredited by the Ai Group as an optional module for the Leadership ll Certificate - a Frontline Management Course.

Statistics Sucks

The participants are introduced to a cannon that can't hit the target. A serious problem experienced by every company, every day!?

We use a touch of Juran, a pinch of Pareto, a dab of Ishikawa and a generous sprinkling of Deming. Hey presto! The problem is solved - and not a headache in sight. Who were these guys anyway that they should confuse us with statistics when all we needed was a bit of team based common sense?

This short course covers the concepts:
Process Measurement
Process Capability
Variability Reduction
Process Improvement

Team Building

Having a workforce that is motivated, flexible and willing to work together is every manager's dream. This really can be achieved over time if the right environment and foundation exists, and if the employees understand how to draw on their total pool of talent.

Team members need a whole suite of new improvement skills today to contribute fully to the future of the company. If delivered all at once, they tend to be quickly forgotten. Optim's approach to team building provides the people short injections of interactive training over an extended period of time, which progressively builds a portfolio of new and useful abilities.

Through Optim's progressive approach, people gradually learn and try things out, so gaining confidence and proficiency. This leads to a sustained and stable team environment.

The Ills Of Inventory

Inventory is the manifestation of all the ills we live with in industry. Why is it there? What does it cost? What can we do about it?

This program is designed to help operational people to understand the effect that inventory has on lead-time, operating costs and service levels. It puts inventory reduction in context with other concepts for continuous improvement and explains the contribution that everyone can make to avoid accumulation of materials and all other resources.

Value Adding Machines

Value Adding Machines embodies the best principles of Total Productive Maintenance into a simple step-by-step process to helping operators and their maintenance colleagues to work together to achieve optimum performance from the value adding equipment.

Value Adding Machines targets:
zero downtime
zero material waste
machines that get better over time

The Value Adding Machines process transfers daily maintenance responsibilities to operators and provides maintenance crews with a framework for the longer term management of equipment effectiveness.

Value Added Productivity Analysis

Peter Drucker said that total enterprise productivity is the only true measure by which to judge and reward the efforts of management and employees. Value Added Productivity Analysis [VAPA] is becoming the means by which companies are determining how effectively capital, equipment and labour resources are being used. The output of this very comprehensive analysis is providing the means for:

enterprise performance measurements
enterprise agreements
enterprise benchmarking
uniting all employees through a common cause - to create wealth for all stakeholders

Work-Centre Improvement

This unique program by Optim helps operators and maintenance personnel on process lines to decide for themselves how to get the best out of their equipment. Workcentre Improvement uses operator experience and our tools for analysis to identify the end products critical-to-quality requirements. They then determine the inputs and skills required to achieve those outputs. The team then drafts its own work instructions, decision rules and monitoring procedures to ensure the critical-to-quality outputs are maintained. The program turns into a project to address skills and knowledge deficiencies and to standardise work practices. In this way, Workcentre Improvement totally compliments ISO 9000.

Workplace Redesign

The drive to reduce batch sizes, to improve response time, quality and flexibility, has encouraged many companies to rethink the way in which they organise their total manufacturing resource. For high, medium and some low repetition industries, Group Technology and Cellular Manufacturing provide the means for achieving these and many other benefits without the need for additional equipment. This program covers all the essential design issues for plant engineers and management, including level scheduling, visual management, JIT, kanban, etc.

Optim Pty. Ltd
Suite 3, 5-7 Chandler Rd
Boronia VIC 3155
Tel: +61 3 97620043 Fax: +61 3 97620071 Email: info@optim.com.au