404. Manufacturing Transformation Strategy: Maturity and Roadmap Modeling

Course Length:

CoC Classroom:  3 Hours; Post Event: 60 minutes for self-study and out-course assessment test
CEUs:    0.4


Many manufacturers attempt Continuous Improvement (CI) initiatives without an aligned MOM system strategy and fail. Many manufacturers attempt MOM systems without an aligned CI initiative and fail. As a result, a new global industrial revolution has begun based on how to optimize manufacturing plants by combining CI methods with an adaptive MOM system architecture put into place using a Manufacturing Transformation Strategy.

The course details the building of a Manufacturing Transformation Strategy by combining two frameworks:
- A Manufacturing Maturity Model supporting the manufacturing transformation strategy
- The ISA-95 methods mapped against this Maturity Model to support the MOM System and CI Roadmap

In the Roadmap, each MES/MOM project ROI identifies corrective actions to mitigate risks through required change to organization structure, process, personnel and technology.

Industrial companies traditionally view manufacturing cost reduction as only a labor cost issue. It is not even the largest cost. Significant cost reduction is a matter of effective work processes across plants and supply chain operations for normal and abnormal operating states. The real solution for effective work processes requires simultaneous changes in organization structure, operations processes, and employee skill sets all of which are enabled by manufacturing operations management system (MOM) technologies.

Successful optimization centers on prevention of production issues in the design by characterizing operations work processes through Lean and Six Sigma methods. Based on the resulting user and system functional requirements, a MOM System Roadmap is derived including risks and a tangible return on investment (ROI) identified for each project. However, when the MOM System Roadmap lacks cultural transformation requirements for each system, the system projects fail.

Learner will be able to:

1. Discuss why a Manufacturing Transformation Strategy is needed
2. Describe a framework to support the definition of such a strategy
3. Explain tools, such as ISA-95, that can help to define a Mfg System Roadmap and Capability Matrix
4. Identify common MES/MOM pitfalls and risks

Learner will cover:

1. Constructing the manufacturing transformation strategy
    a. The manufacturing maturity model
    b. Applying isa-95 models to develop transformation deliverables
2. The processes domain
3. The structure domain
4. The people domain
5. The IT domain
6. Overview of ISA-95 methods used
7. Manufacturing system roadmap definition
8. MOM Success Requires ReOrganization and Alignment of Corporate and Plant Priorities
9. ROI Overview
10. The illusion, "When we finish the project we're done"
11. The reality: progressive insight
12. Frequent pitfalls and possible countermeasures

Assessment Test and Exercises:

1. In-Course Formative Assessment Test: 10 Questions, Open notes in discussion, Answers recorded in Test Form
2. Out-Course Summative Assessment Test: 10 Questions, Open notes in self study, Answers recorded in Test Form

Course Prerequisites: None

Reference Materials:
1. MESA White Paper 38: Building a Manufacturing Transformation Strategy with ISA-95 Methods