COURSE OVERVIEW:

The meaning of process excellence and lean methodologies in energy management refers to the integration of continuous improvement frameworks and waste-reduction principles into the technical administration of energy assets. This course focuses on the application of "Lean" and "Six Sigma" tools to identify and eliminate the "Eight Wastes" as they relate specifically to energy, such as over-generation, idle running, and inefficient thermal transfer. By aligning process efficiency with energy conservation, organizations can move beyond hardware-based solutions to create a self-sustaining culture of operational energy excellence.

The scope of this training encompasses the technicalities of Value Stream Mapping (VSM) for energy flows, the implementation of "Kaizen" events for energy-intensive units, and the utilization of "Total Productive Maintenance" (TPM) to ensure equipment reliability supports efficiency. It examines the impact of process variance on energy intensity, providing a comprehensive methodology for stabilizing operations through "Statistical Process Control" (SPC). The course provides a deep dive into the development of Visual Management systems and real-time dashboards that empower shop-floor operators to take immediate action against energy waste.

Coverage includes the analysis of "Root Cause" energy losses, the implementation of "Poka-Yoke" (mistake-proofing) for energy setpoints, and the reduction of "Changeover" times to minimize energy-intensive startup cycles. The course addresses the critical role of "Standard Work" in ensuring that energy-efficient operating procedures are followed consistently across all shifts. Participants will gain practical expertise in conducting Lean-Energy audits, calculating the financial impact of process "Muda" (waste), and formulating strategic roadmaps that prioritize human-centered operational improvements alongside technical upgrades.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Define the core principles of Lean and Six Sigma in the context of energy.

2.  Identify the "Eight Wastes" (Muda) specifically within energy-intensive processes.

3.  Utilize Value Stream Mapping (VSM) to visualize and optimize energy flows.

4.  Implement "Kaizen" events focused on rapid energy efficiency improvements.

5.  Apply "Statistical Process Control" (SPC) to minimize energy intensity variance.

6.  Design "Visual Management" dashboards for real-time energy monitoring.

7.  Implement "Total Productive Maintenance" (TPM) to support energy reliability.

8.  Develop "Standard Work" procedures for energy-efficient equipment operation.

9.  Utilize "Root Cause Analysis" (RCA) to investigate energy performance gaps.

10.  Design "Poka-Yoke" solutions to prevent energy-wasteful operating errors.

11.  Minimize energy-intensive "Changeover" and "Startup" times through SMED.

12.  Formulate a strategic Lean-Energy roadmap for an industrial facility.

TARGET AUDIENCE:

This course is designed for Continuous Improvement Managers, Process Engineers, Energy Managers, Operations Directors, and Quality Assurance Professionals seeking to merge Lean methodologies with energy management.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.