Operational Excellence Program

IOE Operational Excellence Program

Building a Culture of Excellence through Lean PrinciplesThe IOE Operational Excellence Program is a 10-module training series designed for beginner and intermediate Continuous Improvement practitioners seeking to develop their expertise in Lean Thinking and the Toyota Production System (TPS). Starting January 29th, this program offers practical tools, foundational knowledge, and leadership insights to help participants drive efficiency, productivity, and a culture of continuous improvement within their organizations.

Expert-Led Training

This program is taught by world-class instructors with decades of experience implementing TPS principles:

Sensei Akinori Hyodo: Former Toyota Factory Manager and Kaizen Leader.
Dr. Bob Emiliani: Renowned Lean Leadership expert and author.
Peter Cox: Former senior leader at Toyota and Lean practitioner.
David Fitzpatrick: Specialist in creating people-focused cultures of operational excellence.

PROGRAM OUTLINE

Introduction to TPS and Lean Thinking

Instructor: D. Fitzpatrick

Content:

Overview / Historical background of Toyota Production System (TPS)
Key principles of TPS: Value, Waste, Flow, Pull
Case studies of successful JIT implementation
Homework preparation for next class

Learning Outcomes:

Understand the “need” to improve and the systems created to facilitate improvement.
Gain an in-depth understanding of JIT systems and how to incorporate this thinking into your organization.

Principles of Waste Elimination

Instructor: D. Fitzpatrick

Content:

Types of waste (Muda, Mura, Muri)
7 types of waste and examples
Homework preparation for next class

Learning Outcomes:

Understand waste and its impact on your organization.
Learn to analyze waste and set standards to improve the situation.

Just-in-Time (JIT) and Pull Systems

Instructors: D. Fitzpatrick and Bob Emiliani

Content:

JIT principles and benefits
Kanban system: Basics and implementation
Homework preparation for next class

Learning Outcomes:

Gain an understanding of JIT systems and how to incorporate this thinking into your organization.

Continuous Improvement (Kaizen)

Instructors: D. Fitzpatrick and Bob Emiliani

Content:

PDCA (Plan-Do-Check-Act) cycle
Kaizen events and daily Kaizen
Practical exercises on identifying improvement opportunities
Homework preparation for next class

Learning Outcomes:

Learn how to create and sustain a Kaizen culture in any organization.

Lean Tools and Techniques I

Instructors: D. Fitzpatrick

Content:

5S methodology (Sort, Set in order, Shine, Standardize, Sustain)
Poka-Yoke (error-proofing) techniques
Visual management basics
Homework preparation for next class

Learning Outcomes:

Understand the benefits of sustainable 5S and how improved visual management practices can accelerate your organization.

Lean Tools and Techniques II

Instructors: D. Fitzpatrick

Content:

Total Productive Maintenance (TPM)
Single Minute Exchange of Die (SMED)
Root Cause Analysis techniques (5 Whys, Fishbone diagram)
Homework preparation for next class

Learning Outcomes:

Gain an elevated understanding of the importance of maintenance programs and improved change-over initiatives.

Lean Leadership and Culture

Instructors: D. Fitzpatrick and A Hyodo

Content:

Leadership principles in TPS
Role of management in transformation
Developing a TPS culture and mindset
Homework preparation for next class

Learning Outcomes:

Understand leadership roles within TPS and Lean, and the importance of setting high goals.

Leadership, Continuous Improvement, and Productivity Pt 1

Instructor: D. Fitzpatrick and Peter Cox

Content:

Leadership principles in Lean
Creating a CI (Continuous Improvement) culture
Homework preparation for next class

Learning Outcomes:

Gain a deep understanding of the programs and people needed to install a CI culture in any organization.

Leadership, Continuous Improvement, and Productivity Pt 2

Instructor: D. Fitzpatrick

Content:

Leadership roles in CI
Supporting supplier relationships as part of CI
Productivity improvement through CI initiatives
Homework preparation for next class

Learning Outcomes:

Learn how to better integrate suppliers into your organization’s improvement initiatives.

Lean Implementation – Challenges and Success Factors

Instructor: D Fitzpatrick

Content:

Common challenges in Lean implementation
Success factors and critical steps for effective Lean transformation
Change management strategies in Lean projects
Homework preparation for next class

Learning Outcomes:

Learn from the successes of others and understand what it takes to be Lean.

Akinori Hyodo

Hyodo Sensei is a long-time Toyota Production System Leader, former Factory Manager and Kaizen Leader within the Toyota group. Having retired as Factory Manager, he now heads the Kaizen Training arm of that same Toyota factory, providing lean training courses for companies in Toyota’s supply chain. He was a 13-year member of the renowned All-Toyota Kaizen Promotion Team known as Jishuken. Currently, he consults globally with a wide variety of clients across multiple industries.

Bob Emiliani

Dr. Bob Emiliani has been a progressive management practitioner and researcher for 30 years. He worked in industry for 15 years and held management responsibility in engineering, manufacturing, and supply chain management. Bob was part of a team responsible for implementing TPS principles and practices in both manufacturing and supply chains at Pratt & Whitney. Subsequently, he was a full-time professor for 23 years and now holds the honorary title of Professor Emeritus.

Bob was the first academic to establish a research agenda focused on Lean leadership, resulting in numerous publications and varied leadership development workshops. He is a prolific, versatile, and award-winning writer whose publications span engineering, business, social sciences, and humanities. He has authored or co-authored 28 books and dozens of peer-reviewed research papers across six disciplines: leadership, management, management history, supply chain management, higher education, and materials engineering.

His work is widely recognized, and he is praised for being a unique voice and creative thinker.

Peter Cox

Peter Cox is the Director of Simply Lean Business Solutions Limited in Canterbury, New Zealand. With more than 20 years in senior management roles at Toyota, New Zealand, Peter has amassed extensive experience in engineering, production, quality, training, and human resource development. He has also held key positions as Senior Group Leader for Toyota UK and production manager for Electrolux New Zealand.

Driven by a passion for seeing companies succeed, Peter provides his extensive expertise and strategic guidance to lead companies forward. He has a proven track record of successfully implementing Lean Thinking and Continuous Improvement programs across various industries in New Zealand and Australia.

David Fitzpatrick (Main Facilitator)

David Fitzpatrick is the Co-Founder of Zenkai Improvement Partners, a lean management consulting firm that delivers corporate trainings, seminars, and experience-based study tours. Since leaving his position as a Senior Consultant at one of the region’s top manufacturing consultancies in 2020, David has been offering remote and in-person consulting services to clients from his base in western Japan.

A passionate practitioner of all things TPS and Kaizen related, he welcomes the challenge of helping learning organizations in their pursuit of operational optimization and the development of people-centric cultures.

PROGRAM DETAILS

Enrollment: Now open on a first-come, first-served basis.
Class Size: Minimum of 20 and maximum of 25 students per intake.
Duration: 6 months
Start Date: January 29th, 2025
Enrollment Deadline: January 25th, 2025
Format: Live streaming
Pricing: – IOE Members: CAD 885.00 + HST
– Non-Members: CAD 1,770.00 + HST

For more details about enrollment, contact us at: alex.mihara@cme-mec.ca