Course 17: Selecting the Right Manufacturing Improvement Tools (1-Day)

At the latest count there were some one hundred tools for improving manufacturing performance. At times the selection process can be overwhelming. At other times, a tool is selected, and gains are achieved, only to disappear within a year or two. How do we know what improvement tool is best suited for our organization? How do we know when to apply it? What are some of the fundamental issues we must address, regardless of the tools selected? This seminar is designed to enable you to relate your circumstances and issues to the tools and techniques, so that you can best decide which are relevant for you. It will help you select the right tools, at the right time, for the right problem, and then sustain the improvement achieved.

This course is only offered as a private offering at a client’s site. Please contact PII for details about having our training provided at your site.

Selecting the Right Manufacturing Improvement Tools Course 17 | Process Improvement Institute

Recommended prerequisites: None.

Typical Course Candidates

  • Managers – Production, Maintenance and Executive
  • Engineers – Reliability, Process, Safety
  • Support Staff
  • Anyone who leads or influences the direction and success of manufacturing plants

What You Will Learn

  • Foundational Elements for Manufacturing Excellence
  • How to select the right improvement areas
  • Specific guidelines for developing written programs tailored for each PSM element
  • How to avoid costly defects
  • The tools learned will include: Lean Manufacturing, Six Sigma, Kaizen, TPM, Supply Chain Management, RCM, Predictive Maintenance, and Root Cause Analysis
  • For each tool:
    • Individual tool strengths, weaknesses, where and when they work best, when they might not work, how to align the organization for their use, and so on
    • Additional training necessary for implementation of specific tools

Take Home:

  • Comprehensive course notebook containing
    • Training material on all the tools included in the course
    • Take home appendices and workshops
  • Certificate of Completion
  • 0.7 CEUs & 0.7 COCs

Course Outline (1-day, 8:00 a.m. to 4:30 p.m.)

Overview of Manufacturing Business Excellence:

  • Overview of manufacturing excellence; low cost producer profile
  • The Reliability process for manufacturing excellence
  • Leadership principles
  • Change Management

The Tools:

  • Business Level FMEA – Selecting the right improvement projects and tools
  • Lean Manufacturing
  • Kaizen
  • Total Productive Maintenance (TPM)
  • Six Sigma
  • Supply Chain Management
  • Reliability Centered Maintenance (RCM)
  • Predictive Maintenance
  • Root Cause Analysis


  • OEE as a Means of Measuring and Managing Waste
  • Business Level FMEA – Case Studies
  • Performance Measurement Cascade
  • Maintenance Planning and Scheduling
  • Quick Changeover Process
  • Shutdown/Turnaround Management


  • Potential Class Workshops:
    • Business Level FMEA
    • Case Studies – Review and Decide What You Would Do
    • Personal Reflection and Action Plan
  • Take Home Workshops:
    • Business Level FMEA – Clean, Inspect, Restore – At Your Plant
    • Developing Your Action Plan for Manufacturing Excellence
    • Self Audit of Management Support and Plant Culture
    • Self Audit of Operating Practices
    • Self Audit of Maintenance Practices
    • Assuring Process Consistency during Normal Operations
    • Optimization of Your PM Practices

Ron MooreRon Moore is the primary instructor of this course and the writer of the related textbook. In addition to 30 articles, Ron has written the books What Tool? When? Selecting the Right Manufacturing Improvement Tools and Making Common Sense Common Practice: Models for Manufacturing Excellence. His insights are based on working with hundreds of manufacturing plants helping them to achieve manufacturing excellence. Ron served for five years as President of Computational Systems, Inc (CSI), the leading supplier of industrial instruments and software for equipment condition monitoring technologies. During his five-year tenure, the company grew at 30% per year, while concurrently maintaining healthy profits and cash position, and a strong balance sheet. He holds a BSME, MSME, MBA, PE, and CMRP.

Feel free to contact Ron Moore at 1.865.675.7647 or by email at