Operational Excellence for Process Industries

 “Application of Lean Principles for Process Industries calls for understanding its uniqueness in the context of PQCDSM”

 Programme Overview

Process industries entail heavy capital investment, restrictions on layout changes, higher levels of environmental and safety impact, seasonality of input, shelf life of material at all levels and material flow in batches. Adapting Quality methodologies like Lean, Six Sigma, TPM, TQM to be relevant for process industries will go a long way in creating operational excellence.

 Programme Benefits:

  • Applicability and adaptation of various methodologies like 5S, SoP, Skill Matrix, Autonomous Maintenance to enable stability
  • Measurements appropriate for process industries to enable stability like OPE, MTTR, MTBF, Process Capability index, etc.
  • Integration of various Operational Excellence tools like Maki Gami, Value Stream Mapping, Kaizen, Maintenance Experience Map, TPM Pillars.
  • Addressing Safety, Health and Environment challenges
  • Ways to adopt Discrete manufacturing methodologies to Process

Programme Objectives:

By the end of the programme, the participants will understand:

  • Adapting the Opex journey to Process industry
  • Integrating Safety, Health and Environment to the journey
  • Adopting the relevant tools to process industry

Programme Content:

  • Uniqueness and Challenges of Process Industries
  • Muda, Mura, Muri – discovering waste, variability and strain to enable Operational Excellence
  • Process Stability
  • Adaptive Measurements
  • Sixteen Big Losses
  • Work Place Organisation involving 6 Senses, and integrating Safety, Health and Environment
  • Process Improvement:
  • Categories of Legitimate Reservation – Base of Root Cause Analysis
  • Root Cause Analysis
  • Relevant methodologies – TPM, Maki Gami, Gemba Walk
  • Disruptive Technologies and Capacity Creation

Who should attend? Leaders from Operational Excellence, Quality movement, Manufacturing, Maintenance


Interactive sessions, breakout exercises, creating insights through the participants’ experience. Live Cases from the industry will be discussed.

Contact Us

Bhavan's Campus
Munshi Nagar | Dadabhai Road,
Andheri West | Mumbai - 400 058, India
Reach us at:
Reception: +91 22 61454200
Delhi Centre
Bharatiya Vidya Bhavan Campus, 
3rd Floor Gate No. 4, Copernicus Lane
Kasturba Gandhi Marg, New Delhi-110001
Telephone: 011-23073121, 011-23006871
Direct Line: 011- 23383563

Link to SPJIMR Location Google Map