Operational Excellence

Learning Outcomes

By the end of this course, learners will be able to:

• Understand and apply the principles of Operational Excellence in manufacturing.
• Deploy Lean, Six Sigma, and TPM tools for process optimization and waste elimination.
• Integrate Industry 4.0 technologies into operational improvement initiatives.
• Manage change and build a continuous improvement culture.
• Align operational excellence with ESG, EHS, and sustainability goals.
• Lead cross-functional teams to execute operational excellence projects with measurable business outcomes.
• Benchmark and apply global best practices in OpEx across manufacturing sectors.

Modules & Topics

Module 1: Foundations of Operational Excellence (1 ECTS)

• Defining Operational Excellence in manufacturing
• Operational Excellence frameworks (Shingo, Toyota Production System, Baldrige)
• The business case for OpEx

Module 2: Lean Principles and Tools (1.5 ECTS)

• Value Stream Mapping
• 5S, Kaizen, and visual management
• Standard work and takt time
• Waste identification and elimination in manufacturing

Module 3: Six Sigma and Quality Management (1.5 ECTS)

• Six Sigma principles (DMAIC, DMADV)
• Process capability analysis
• Statistical process control (SPC)
• Root cause analysis and problem-solving tools
• Quality management systems (ISO, TQM)

Module 4: Total Productive Maintenance (TPM) and Asset Management (1 ECTS)

• TPM pillars and implementation roadmap
• Autonomous and planned maintenance
• OEE (Overall Equipment Effectiveness)
• Reliability-centered maintenance

Module 5: Industry 4.0 and Smart Operations (1.5 ECTS)

• IoT and sensor-based monitoring
• Predictive maintenance using AI/ML
• Digital twins and factory simulations
• Cybersecurity in manufacturing operations

Module 6: Supply Chain Excellence (1 ECTS)

• Aligning supply chain and operational excellence
• JIT, Kanban, and pull systems
• Supplier integration and quality
• Agile and resilient supply chains

Module 7: Sustainability, ESG, and EHS Integration in OpEx (1 ECTS)

• Sustainable operations and circular economy
• ESG frameworks and reporting in manufacturing
• EHS compliance and safety culture
• Energy management and carbon footprint reduction

Module 8: Leadership and Change Management for OpEx (1 ECTS)

• Building a culture of continuous improvement
• Change management frameworks (Kotter, ADKAR)
• Leading cross-functional teams for OpEx
• Measuring and sustaining operational excellence initiatives

Module 9: Benchmarking and Global Best Practices (0.5 ECTS)

• Benchmarking OpEx in manufacturing sectors
• Case studies: Siemens, Toyota, Tata, Bosch
• Applying global standards in local contexts

Pedagogy

• Case studies from chemical, textiles, agrochemical, and pharma sectors
• Factory simulation games and digital twin exercises
• Interactive workshops on value stream mapping, SPC, and OEE analysis
• Guest lectures from IIM, IIT, ICT, and global industry mentors
• Capstone projects aligned with learners’ workplace challenges
• Continuous assessments for reflective learning and real-world application

Assessment Structure

Capstone Project

Learners will undertake a real-world Operational Excellence project in their organization (or a simulated project) focusing on:

• Lean implementation
• Waste reduction
• Process capability improvement
• TPM rollout
• ESG alignment
• Measurable business outcomes (cost savings, quality improvement, lead time reduction)

This project will be evaluated by Mentogram mentors with mid-project and final presentations.

Certification

On successful completion, learners will receive:

• “Operational Excellence for Manufacturing Industry Leaders” module completion certificate with 10 ECTS credits under Mentogram’s Global TEMBA program, accredited under European Standards.