Course Title:
Production Management for Cost Reduction & Efficiency Improvement
Course Duration:
2-3 Days (Customizable)
Target Audience:
- Production Managers & Supervisors
- Operations Managers
- Process Engineers
- Supply Chain & Logistics Managers
- Continuous Improvement Teams
- Anyone responsible for production efficiency & cost control
Course Objectives:
By the end of this course, participants will be able to:
- Understand key principles of production management for cost efficiency.
- Identify waste and inefficiencies in production processes.
- Apply Lean, Six Sigma, and other efficiency improvement techniques.
- Develop strategies for optimizing production planning and scheduling.
- Implement cost reduction initiatives without compromising quality.
- Use data-driven decision-making for process improvement.
- Enhance supply chain and inventory management to reduce costs.
- Foster a culture of continuous improvement and operational excellence.
Learning Outcomes:
Participants will:
✅ Gain a strong understanding of cost drivers in production management.
✅ Learn to map and analyze production processes to identify inefficiencies.
✅ Master tools like Value Stream Mapping (VSM) and Root Cause Analysis.
✅ Apply Lean Manufacturing, 5S, and Kaizen to reduce waste.
✅ Optimize resources, workforce planning, and machine utilization.
✅ Improve demand forecasting and inventory management techniques.
✅ Reduce downtime through preventive & predictive maintenance strategies.
✅ Develop action plans for implementing cost-saving initiatives.
Course Outline:
Module 1: Introduction to Production Management & Cost Efficiency
- Importance of Cost Control in Manufacturing
- Key Performance Indicators (KPIs) for Efficiency Improvement
- Role of Technology in Modern Production Management
Module 2: Analyzing Production Costs & Identifying Waste
- Breakdown of Production Costs (Direct & Indirect)
- Identifying the 7 Wastes of Lean Manufacturing
- Cost-Benefit Analysis for Process Improvements
Module 3: Lean & Six Sigma for Cost Reduction
- Lean Principles & How They Improve Efficiency
- Introduction to Six Sigma & Process Optimization
- Case Studies of Successful Lean Implementations
Module 4: Process Optimization Techniques
- Value Stream Mapping for Waste Reduction
- Root Cause Analysis (5 Whys, Fishbone Diagram)
- Cycle Time Reduction & Bottleneck Elimination
Module 5: Smart Production Planning & Scheduling
- Demand Forecasting & Inventory Management
- Just-in-Time (JIT) & Kanban for Cost Efficiency
- Resource Allocation & Workforce Optimization
Module 6: Technology & Automation for Efficiency
- Role of Industry 4.0 & IoT in Production Management
- Implementing Digital Tools for Real-Time Monitoring
- AI & Predictive Maintenance for Cost Savings
Module 7: Quality Management & Cost Control
- Cost of Poor Quality (COPQ) & How to Reduce It
- Statistical Process Control (SPC) for Quality Assurance
- Standardization & Process Documentation for Consistency
Module 8: Continuous Improvement & Sustainability
- Building a Culture of Continuous Improvement
- Employee Engagement & Training for Efficiency Gains
- Sustainable Manufacturing Practices & Cost Reduction
Module 9: Action Planning & Implementation
- Developing an Action Plan for Cost Reduction
- Change Management & Overcoming Resistance
- Measuring & Sustaining Improvements Over Time
Training Methodology:
This course uses a mix of:
✅ Instructor-Led Presentations – Concept explanations with real-world examples.
✅ Case Studies & Industry Best Practices – Learning from successful cost-reduction strategies.
✅ Interactive Workshops & Group Activities – Hands-on exercises for practical application.
✅ Process Mapping & Problem-Solving Exercises – Identifying real inefficiencies in production.
✅ Role-Playing & Simulations – Applying Lean & Six Sigma techniques.
✅ Action Planning & Implementation Guidance – Personalized strategies for workplace application.
Assessment & Certification:
- Pre & Post-Training Assessments to measure knowledge gain.
- Practical Exercises & Group Projects for real-world application.
- Certificate of Completion upon successful participation.