Who this course is for
Industrial Engineers, OpEx Leaders, Production Managers, Supervisors and Plant Managers responsible for work design, time studies and productivity improvement.
Why this course matters
Productivity is often managed through pressure and targets — without understanding what operators actually do. This course teaches how to observe, measure and improve work in a way that is sustainable and respectful of people.
What you will learn
- Work Studies and Gemba observation methodology
- Activity breakdown and time recording
- Yamazumi charts — operator load balancing
- Standard Work design and documentation
- Abnormal work mapping
- ERACS: Eliminate, Reduce, Automate, Combine, Simplify
- SMED — changeover reduction
- Ergonomics and human factors
- REFA Standards — Average Time, Normal Time, Performance Coefficient, Standard Time
- Allowances — fatigue, personal needs, unavoidable delays
- Operator Occupation Rate and Abnormality Response Time
- Idle time interpretation — necessary vs wasteful
Course structure
- Module 1: Work observation — how to see work clearly
- Module 2: Time recording and activity breakdown
- Module 3: Yamazumi — visualising and balancing operator load
- Module 4: REFA Standards — average time, normal time, standard time
- Module 5: Allowances — fatigue, personal, unavoidable delays
- Module 6: Operator occupation and idle time interpretation
- Module 7: ERACS and SMED
- Module 8: Standard Work design and ergonomics
- Module 9: Productivity improvement plan
What you will be able to do after this course
Conduct work studies at the Gemba, calculate standard times using REFA Standards, build Yamazumi charts, identify productivity improvement opportunities and design improvements that are sustainable and respectful of operators.
Duration and format
25–36 hours over 4–6 weeks
Practical Gemba-based course — work observation, analysis, improvement project.