SUSTAINING LEAN IMPLEMENTATION IN CHEMICALS MANUFACTURING

Transcription

1 SUSTAINING LEAN IMPLEMENTATION IN CHEMICALS MANUFACTURING Date: April 2017 Venue: Holiday Inn Mumbai International Airport Understanding and mastering various provisions to help implement and build a lean culture in the organization to ensure that the processes remain defect-free, stable, and competitive in the market OVERVIEW: Lean has been promoted as a set of tools for over two decades. The consequence has been a series of initiatives in a large number of Chemical manufacturing organizations, with mixed results. While a few exceptional companies have been able to sustain the benefits & keep improving, a majority have floundered. The long term success has been abysmally low. The Indian chemical industry is at a transition point between a phase of extensive scale building, and becoming a global leader. And one of the imperatives to make that shift happen, bringing a potential EBITDA impact ranging from an additional 4 to 7 percentage point is through changes required in manufacturing excellence. Lean Management offers a path to building sustainable competitive advantages over a relatively short span of time at the same time benchmark processes for a long term. Researchers have arrived at the root cause, when lean is developed as a way of thinking and a culture it sustains. Culture building is easier said than done; it must happen top down & it must result in new behaviors. This 2-day highly interactive and practical course will assist chemical, petrochemical, pharma manufacturing companies in achieving a competitive advantage by having an effective and well- managed operation. This program is designed to help leaders understand the ways of thinking, behaving & leading that builds a sustainable lean culture in an organization. MASTER CLASS PARTNER ORGANISED BY MEET THE TRAINER: Gopinath Prabhu Senior Consultant & Leader Training (India & Africa) Kaizen Institute Gopinath Prabhu, B.Sc, B.Tech, is associated with Kaizen Institute India from last 4 plus years as Sr. Consultant & Leader Training (India & Africa). As a consultant in the field of Operational excellence, he has helped many Clients in implementing Kaizen & lean concepts. His clientele includes state & central govt. institutions, a large network of govt. hospitals, pharma companies, steel, telecom, aluminium & automotive component manufacturing industries in India & in Africa. He enjoys training & coaching assignments and he has trained hundreds of Managers, Engineers, Doctors, clinical & non-clinical staff, Officers of different levels in State & Central Govt. offices on Kaizen, TQM & Lean tools. Prior to Consulting career, Gopinath has 32 years of experience with four different industries, viz., Computer Peripherals manufacturing, IT & IT Training, Telecom & BPO. He was previously a Vice President (Quality, Training & Knowledge management services) with Customer care division of Reliance Infocom. After engineering degree in 1980 from MIT, Madras, he started his career as R&D Engineer but later took interest in Manufacturing & Quality Management functions. His 11 years stint with TVS group, where he got opportunity to learn TQM & Lean concepts from some of the famous JUSE (Union of Japanese Scientists & Engineers) Professors & Consultants, helped him to develop strong foundation in Lean philosophy. Gopinath is a Certified Manager in TQM principles from AOTS Japan & Certified Six Sigma Black Belt from ASQ. He has championed many process improvement projects to reduce TAT, reduce inventory, improve productivity & reduce cost of servicing a Customer. learning provider.

2 LEAN- CHANGE MODEL SET TRUE NORTH Where do you want to go? SUSTAIN DAILY (Built in daily behaviours) ENGAGE LEADERS (Their paradigms, measures and actions) MAKE IMPROVMENTS (Get Breakthroughs) SUPPORT QUALITY AND KAIZEN (Governance -steering) KAIZEN Change Model KCM has five building blocks. True North Project KAIZEN Daily KAIZEN Leader KAIZEN Support KAIZEN Globally it has been observed by the Kaizen Institute that these five elements or building blocks need to be addressed and adhered to, if one hopes to change culture! If an organization wants to sustain the Kaizen spirit of continual improvement, this is the model to understand and adopt. Lean Culture is about: Daily Problem solving Daily Standards and practices Daily KAIZEN! Daily Improvements Daily is one of the keys to culture change. What ones does daily results or impacts what is achieved daily, weekly, quarterly and so on. The big question is how does one sustain the improvements made and the improvement spirit. The sessions explores and help the participants grasp the significance of the: Framework for transformational culture building Daily KAIZEN and its role Lean tools box for culture building Lean performance management Role of leaders in building a lean culture Coaching a key lean skill

3 TOPICS TO BE COVERED THE FRAMEWORK FOR TRANSFORMATIONAL CULTURE BUILDING PERFORMANCE MANAGEMENT TO DRIVE A LEAN CULTURE 02 CREATING A CULTURE OF SUSTENANCE AND CONTINUAL IMPROVEMENT THROUGH 05 DAILY KAIZEN ROLE OF LEADERS IN BUILDING A LEAN CULTURE THE LEAN TOOLBOX AND CULTURE BUILDING THE ART AND SCIENCE OF COACHING IN LEAN CULTURE BUILDING WHO SHOULD ATTEND FROM WHICH INDUSTRIES? MANAGING DIRECTORS, VICE PRESIDENTS, DIRECTORS, GENERAL MANAGERS, HEADS, MANAGERS FROM: PRODUCTION MANUFACTURING OPERATIONS BULK CHEMICALS SPECIALITY CHEMICALS AGROCHEMICALS PLANT ENGINEERING FERTILIZERS QUALITY ASSURANCE QUALITY CONTROL PETROCHEMICALS SUPPLY CHAIN STRATEGIC PLANNING PHARMACEUTICALS BUSINESS & PROCESS IMPROVEMENTS SUPPLY CHAIN & PROCUREMENT INVENTORY MANAGEMENT

4 TRAINING DAY 1 / 24 th APRIL 2017 TRAINING DAY 2 / 25 th APRIL Registration and coffee 9.00 Introduction: Create the culture Program structure Overview of Kaizen Star game Session 1: The framework for transformational culture building The importance of Paradigms in change management Resistance to change- a myth? Behaviors and culture setting Key Principles essential for an OE culture _ Customer orientation, People orientation, Gemba orientation, Process orientation & Scientific orientation 4 corners game Coffee Break Session 2: Direction setting for Change management Understanding Value from a customer perspective Defining the true North Organizational readiness for deployment Cascading goals to all levels The deep significance of Catch Ball Mechanisms for controlling the journey Re-evaluating the True North Lunch Session 3: Creating a culture of sustenance and continual improvement through Daily KAIZEN Understanding Daily KAIZEN - Beeping squares game Creating employee engagement and empowerment Critical standards and visual controls Leader Standard Work Layered daily accountability process Coffee Break Session 4: The lean toolbox and Culture building Process transformation leading to culture change Systematic approach to process transformation Implementing improvement project- key caution points The Link to leadership in process improvement Case study on Process Improvement End of Day 1 of Training 8.00 Registration and coffee 9.00 Recap of Day One 9.30 Session 5: Performance management to drive a Lean Culture What to measure and what not to measure. Mission Control room to control and navigate Group work designing a Mission Control room Role of Support systems -communication, R&R, skill development & auditing Coffee Break Session 6: Our roles as leaders in a building a lean culture Case study on leadership Self development begins with learning Leadership learning cycles Hansei ( reflection) the key to self- development Modeling for the expected behavior Lunch Session 7: The art and science of Coaching in lean culture building Catch Ball game The leaders job in developing people The coaching Kata Learning to ask questions Helping people scale the change curve Commitment to developing leaders at all levels Coffee Break Closing session Summary Key skills of leadership Q&A Feedback Action plans End of Training SUSTAINING LEAN IMPLEMENTATION IN CHEMICALS MANUFACTURING

5 MASTER CLASS PARTNER It has been 31 years since Masaaki Imai wrote Kaizen: The Key to Japan s Competitive Success (McGraw Hill 1986), and the founding of Kaizen Institute. Future historians will no doubt mark this date in 1986 as one of the turning points in the progression of quality, productivity, and labour-management relations. Indeed, we believe that KAIZEN, along with information technology and the globalization of supply chains and services, are the top three economic innovations of the 20th century and these will have made a lasting positive effect on the world economy into succeeding centuries. Kaizen Institute Consulting Group (KICG) was founded by Masaaki Imai, pioneering the original KAIZEN consulting firm, specialized in continuous improvement and achieving enterprise wide business excellence. Today, KICG is a global consultancy active in all sectors. Since their humble beginnings, they have come a long way in making great strides and significant contributions to our world through KAIZEN. KICG is a global organization which introduced KAIZEN Methodology to the world in It has access to global experience & does research, publish and license various publications including books, training materials and online learning. KICG develop their own IP and their domain is in Operational Excellence. This is what they have focused on from last 31 years and have supported more than 50 countries. Kaizen Institute India (KII) is the business unit of KICG. KII provides consulting, training, and lean enterprise transformation services to companies in Europe, Asia-Pacific, Africa, Middle East and the Americas. The company s service portfolio primarily focuses on consulting, training, benchmarking, and qualification (certification) areas. It facilitates clients to implement KAIZEN based business strategies. in.kaizen.com ORGANISED BY Inventicon stands for Industries + Events + Ideas + Concepts. Inventicon Business Intelligence is the end result of a decade long effort by the founders in the space of business information. We develop sector focused informational conferences and training workshops. Our conferences revolve around current scenarios and opportunities in the global market place and provide timely opportunities for solution providers to meet their target market and for end users to take back key learnings and experiences. Our events act as a point of convergence for senior industry professionals who strive for innovation, strategy and commercial drive. Delegates can expect to hear from industry s best practitioners, get in direct contact with regulators and stimulate high level discussions with peers. The training portfolio is dedicated to developing skill sets around complex workplace and functional issues as they need constant honing. Our inhouse training offerings are particularly useful for companies who prefer a customized agenda. The bespoke events portfolio aims at crisp round table discussions involving a targeted group of end users in a multi-city format. In true sense, we aspire to disseminate critical business intelligence to the rapidly growing corporate and institutional world in the country and not limited to a specific sector. For more information visit

6 Registration Form LOCATION AND DATE Sustaining Lean Implementation in Chemicals Manufacturing April 2017 Holiday Inn Mumbai International Airport 3 EASY WAYS TO REGISTER NOW venkat.iyer@inventicon.in Call now on or Mail this completed form together with payment to: Inventicon Business Intelligence Pvt. Ltd. at Times Square, Unit 1, Level 2, B Wing, Andheri Kurla Road, Andheri (East), Mumbai , MS, India. Indian Delegates: Early bird Discounts Book and pay before Mar 31, 2017 Standard Rate Amount in INR 30,000 35,000 Group discounts available for 3 or more delegates (The group discounts compound on top of the early-bird discounts) *Prices are in INR. Additional service tax of 15% is applicable. International Delegates: Early bird Discounts Book and pay before Mar 31, 2017 Standard Rate Amount in USD Group discounts available for 3 or more delegates (The group discounts compound on top of the early-bird discounts) *Prices are in USD. Additional service tax of 15% is applicable. 1) Name:... Job title: ) Name:... Job title: )Name:... Job title: Payment is required within 5 working days from registration. Bank Transfer: Bank Name: HDFC Bank Ltd Account No: Account Name: Inventicon Business Intelligence Pvt. Ltd. IFSC Code: HDFC Swift Code: HDFCINBB Bank Address: Prudential Building, Ground Floor, Hiranandani Business Park, Powai, Mumbai , Maharashtra, India. Credit Cards: Visa, Amex & MasterCard accepted. All payments must be received prior to the event date Company name:... Authorising Manager: Address: Attire: Smart Casual General Information: The fees cover participation at the event, lunch, tea breaks and materials. Confirmation Details: Joining details confirming your participation will be sent, once a registration has been received. For hotel bookings, please contact the Reservations department and quote INVENTICON BUSINESS INTELLIGENCE to take advantage of the corporate rate. Cancellations/Substitutions: Once registration form is received; participation can t be cancelled, however substitutions are welcome at any time. Cancellations carry a 100% liability and course materials will still be couriered to you.