Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Process Engineers
• Planning Engineers
• Production Engineers
• Operation Engineers
• Project Engineers
• Maintenance Engineers
• Technical Staff involved in Process Optimization and De-Bottlenecking

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Build foundational knowledge of process systems, performance indicators, and bottleneck identification
• Equip participants with analytical tools and data-driven techniques to detect and measure bottlenecks
• Explore and apply strategies to increase capacity and reduce waste
• Apply targeted methods to increase throughput by eliminating or mitigating bottlenecks
• Learn how to implement improvements effectively and sustain gains

DAY 1

Fundamentals of Process Optimization & Bottlenecks

• Pre-test
• Introduction to Process Optimization
• Definition and Impact of Bottlenecks
• Key Performance Indicators (KPIs): Throughput, Cycle Time, Yield, OEE
• Process Mapping and Flow Diagrams (SIPOC, Value Stream Mapping)
• Introduction to Lean and Six Sigma Principles
• Constraints vs. Non-Constraints (Theory of Constraints)
• Case Study

DAY 2

Bottleneck Identification and Analysis Tools

• Types of Bottlenecks: Equipment, Labor, Material, Control, Information
• Time Studies and Cycle Time Analysis
• Data Collection and Process Monitoring Tools
• Statistical Tools:

• Pareto Analysis
• Control Charts
• Process Capability Analysis

• Root Cause Analysis Techniques (5 Whys, Fishbone Diagrams)
• Exercise

DAY 3

Process Optimization Techniques

• Process Simplification and Standardization
• Load Balancing and Line Balancing
• Equipment Reliability and Maintenance Strategies
• Inventory Optimization (WIP, Raw Materials)
• Energy and Resource Efficiency
• Continuous Flow and Just-In-Time Concepts
• Case Study

DAY 4

De-Bottlenecking Strategies and Technologies

• De-Bottlenecking Principles and Strategy Development
• Capacity Expansion Options: Equipment Upgrade, Parallelization, Scheduling
• Automation and Digitalization: SCADA, IoT, Digital Twins
• Process Simulation and Modeling Tools (overview of Aspen, Arena, or FlexSim)
• Economic Evaluation: ROI, Payback, Risk Assessment
• Case Study

DAY 5

Implementation, Monitoring, and Continuous Improvement

• Change Management and Stakeholder Engagement
• Implementation Roadmaps and Pilot Testing
• Performance Monitoring and Feedback Loops
• Use of Dashboards and KPIs for Sustained Optimization
• Building a Culture of Continuous Improvement
• Documentation and Reporting Best Practices
• Course Review and Final Q&A
• Post-test