Capability Building
A curriculum for top-decile operational capability.
Modules that are designed, deployed, and refined across industries — organized by practice area and delivered across four audience tiers: Executive Leadership, Mid-Level Management, Shop Floor Teams, and OpEx Leadership.
01
Manufacturing Operations & Operational Excellence
From foundational workplace organization to advanced production system design — the full curriculum to build a world-class manufacturing operation.
Tier 01 · Executive
Manufacturing Leadership
- Operational Excellence Vision WorkshopUnderstanding OE as a system — not a set of tools — and the leader's role in sustaining it
- OEE & Performance BenchmarkingTop quartile and top decile benchmarks; what top-decile OEE performance requires of leadership
- Production System Design PrinciplesHow world-class production systems are structured and what makes them self-sustaining
- Investment Prioritization for OEResource allocation logic for OE programs; linking investment to EBITDA impact
- Continuous Improvement CultureBuilding a culture where improvement is daily habit, not periodic initiative
Tier 02 · Management
OE Practitioner Skills
- Value Stream MappingCurrent-state and future-state mapping; identifying and eliminating waste in the production flow
- Daily Management SystemsTiered DMS structure; visual performance management boards; SQDCP scorecards; escalation protocols
- Visual Performance ManagementDesigning and operating visual management systems that make performance, problems, and priorities immediately visible at every level
- Production Planning & Run-to-ScheduleSchedule adherence discipline; sequencing logic; constraint management and buffer design
- Takt Time & Line BalancingMatching production rate to customer demand; line balance analysis and rebalancing techniques
- OEE Management & Loss AnalysisAvailability, performance, and quality loss categorization; minor stops and speed loss deep-dive
- Problem Solving & Root Cause AnalysisA3 thinking; 5-Why; fishbone; structured problem-solving cadence
- Continuous Improvement WorkshopsDesigning, running, and sustaining focused improvement events and rapid improvement cycles
- Error-Proofing & Mistake-ProofingDesigning processes and equipment to prevent errors at source; detection vs. prevention hierarchy
- Six Sigma & Statistical Process ControlDefect reduction using data; control charts, process capability, and variation reduction
- Standard Work DevelopmentWriting, validating, and sustaining operator and leader standard work documentation
Tier 03 · Shop Floor
Operator Skills
- 5S Foundation & Workplace OrganizationSort, Set, Shine, Standardize, Sustain — with audit frameworks and team-led scoring
- Changeover Reduction / SMEDInternal vs. external elements; single-digit changeover methodology; team-based practice
- Minor Stops & Speed Loss EliminationIdentifying, recording, and eliminating chronic low-level losses
- Autonomous QualityOperator-led quality checks; defect detection at source; first-pass yield discipline
- Autonomous MaintenanceOperator-led daily checks; cleaning, inspection, and lubrication; abnormality identification
- Visual Performance ManagementReading and contributing to team performance boards; understanding the daily scorecard
- Start-of-Shift Meetings & Operator HandoverStructured shift start; performance review; safety; priorities and assignments
- Operational Checks & Monitoring RoundsEquipment checks; process parameter monitoring; abnormality reporting
- Pull System OperationPull-based material flow; signal systems; replenishment discipline
- Error-Proofing in PracticeRecognizing error-proofing devices; using them correctly; reporting when they fail
Tier 04 · OpEx Leadership
OE Program Ownership
- Continuous Improvement Deployment StrategySequencing the improvement deployment to build on itself; avoiding the "tool of the month" failure
- Strategy DeploymentCascading organizational goals to operational actions; policy deployment and review process
- OE System PrinciplesJust-in-time, automation, mistake-proofing, and the systems thinking behind the tools
- OE Maturity Assessment & RoadmappingAssessing current maturity; designing the multi-year improvement trajectory
- Internal Facilitation CertificationEquipping internal leaders to run improvement workshops and problem-solving without external support
02
Logistics & Warehouse Operations
End-to-end supply chain performance — from dock-to-dock warehouse operations to network strategy and 3PL governance.
Tier 01 · Executive
Supply Chain Strategy
- Supply Chain Network StrategyNetwork modeling fundamentals; warehouse footprint optimization; make vs. buy decisions
- OTIF & Customer Service PerformanceWhat top-decile OTIF looks like; the cost of under-performance; leadership levers
- 3PL / 4PL Governance & Vendor ManagementStructuring provider relationships; SLA design; performance review frameworks
- Transportation Cost OptimizationLoad optimization; routing strategy; fuel management and procurement
- Supply Chain Risk & ResilienceIdentifying and mitigating supply chain vulnerabilities; building resilience into network design
Tier 02 · Management
Warehouse Operations Management
- Warehouse Layout & Slotting OptimizationFlow-based layout design; product slotting by velocity; space utilization
- Labor Planning & Productivity ManagementLabor standards; workforce scheduling; productivity measurement and management
- Inventory Management & Cycle CountingInventory accuracy discipline; ABC classification; cycle count program design
- Inventory Planning & AnalysisSetting inventory levels using demand deviation and lead time standard deviation; complex network inventory planning, backfill management, and AI-assisted replenishment
- Turnaround Time ManagementDock scheduling; dwell time reduction; inbound and outbound turnaround discipline
- WMS Implementation & OptimizationWarehouse management system selection, deployment, and ongoing optimization
- KPI Design & Performance TrackingWarehouse scorecard design; leading and lagging indicators; daily visual management
- Reverse Logistics & Returns ManagementDesigning efficient returns processes; disposition logic; cost recovery and customer impact
Tier 03 · Shop Floor
Warehouse Team Skills
- Receiving & Pre-Receipt ProcessesAdvance shipment notice processing; appointment scheduling; dock preparation
- Offloading, Checking & Put-AwayQuantity and quality verification; RF scanner-guided put-away; cross-docking procedures
- Order Picking Strategies & AccuracyPick methods (zone, wave, batch); pick accuracy; error reduction techniques
- Palletizing Standards & Load IntegrityPallet build standards; load stability; weight distribution and wrap requirements
- Staging & Loading DisciplineStaged load verification; truck loading sequence; documentation and sign-off
- Forklift & Equipment Operation SafetySafe operation standards; pre-use inspection; pedestrian interaction rules
- 5S in the WarehouseApplying workplace organization principles in a warehouse environment; sustaining standards
Tier 04 · OpEx Leadership
Supply Chain Excellence
- End-to-End Supply Chain OptimizationIntegrating warehouse, transportation, and network decisions into one system
- Demand-Driven Supply Chain DesignAligning supply chain structure to demand variability; postponement and decoupling point design
- Automation Readiness AssessmentEvaluating where automation adds value in the warehouse; sequencing the transition
- Advanced Analytics for LogisticsDemand forecasting; route optimization; predictive inventory management
- S&OP Process IntegrationConnecting sales and operations planning to warehouse and transportation execution
03
Maintenance & Reliability Practices
The foundational discipline of the RPE practice — built and refined over three decades. Condition-based monitoring is the thread that runs through every module: monitoring and reporting on equipment conditions, then using all available data — including condition monitoring technologies — to drive the right maintenance action at the right time.
Tier 01 · Executive
Asset Management Strategy
- Asset Reliability as a Business StrategyThe financial case for reliability; linking unplanned downtime to EBITDA; top-decile reliability benchmarks
- Maintenance Cost OptimizationTotal cost of maintenance vs. total cost of unreliability; investment prioritization logic
- Asset Management Maturity AssessmentISO 55000 framework overview; current maturity evaluation; the journey to world class
- Capital Planning & Life Cycle ManagementAsset replacement strategy; capital project prioritization; lifecycle cost modeling
- Reliability Culture & LeadershipBuilding a reliability-first culture; leadership behaviors that reinforce or undermine reliability
Tier 02 · Management
Reliability Engineering & Planning
- Maintenance Planning & SchedulingWork order management; job plan development; schedule compliance; planner role and effectiveness
- Materials Management for MaintenanceSpare parts strategy; critical spare identification; storeroom management and inventory optimization
- Shutdowns, Turnarounds & OutagesPlanning, scope development, execution discipline, and post-event learning
- FMEA & Failure Mode AnalysisPhysical and functional FMEA methodology; failure mode prioritization; task selection
- Reliability Centered MaintenanceSeven-step RCM process; consequence of failure analysis; PM optimization
- Condition-Based Monitoring Program DesignDesigning a CBM program that monitors and reports on equipment conditions using all available data streams — vibration, oil analysis, thermography, and ultrasound — to drive the right maintenance action
- Weibull Analysis & Reliability StatisticsFailure data analysis; Weibull distribution interpretation; MTBF improvement planning
- Wrench Time & Productivity AnalysisMeasuring and improving maintenance workforce productivity; wrench time studies
- CMMS Implementation & OptimizationCMMS selection criteria; data structure design; KPI configuration; sustained utilization
Tier 03 · Shop Floor
Technician Skills
- Preventive Maintenance ExecutionReading and executing PM job plans; time standards; quality of completion
- Condition-Based Monitoring TechniquesMonitoring and reporting on equipment conditions using vibration analysis, oil analysis, thermography, and ultrasound — understanding what the data means and when to escalate
- Vibration Analysis — Advanced (ISO Category II/III)Full spectrum analysis; bearing and gear defect identification; diagnostic reporting and trending
- Oil Analysis & Fluid Condition MonitoringBuilding and managing an oil analysis program; integrating sample results with CMMS and maintenance decisions; tribology fundamentals
- Infrared ThermographyThermal imaging for electrical and mechanical condition monitoring; hot spot identification and reporting
- Ultrasonic Leak & Condition DetectionCompressed air, steam, and bearing condition monitoring via ultrasound; interpreting decibel readings
- Precision Alignment & BalancingShaft alignment using dial indicator and laser methods; rotor balancing as a reliability foundation
- Bearing Selection, Installation & ManagementBearing failure modes; correct installation and removal; condition-based replacement practice
- Lubrication Best Practices & TribologyLubrication routes; correct lubricant selection; contamination prevention; tribology — friction, wear, and lubrication as a reliability system
- Defect Identification, Management & PreventionIdentifying and tagging defects in the context of RCM failure prevention; defect elimination workflow; abnormality escalation discipline
- Work Order Execution & FeedbackJob plan adherence; documenting findings; failure code usage; parts consumption recording
- Root Cause Failure AnalysisParticipating in RCFA investigations; gathering physical evidence; failure mode identification
- Safe Isolation & Lock-Out Tag-OutEnergy isolation procedures; LOTO application and verification; permit to work
Tier 04 · OpEx Leadership
Reliability Program Ownership
- Asset Care Program DesignBuilding a site-wide asset care strategy integrating PM, condition-based monitoring, and operator care
- Technician Skills Matrix — Priorities, Tracking & Capability BuildingDesigning and managing a skills matrix for maintenance teams; identifying capability gaps; building structured development plans to close them
- Condition-Based Monitoring Technology StrategyTechnology selection; sensor and monitoring system design; integrating CBM data streams with CMMS and analytics platforms
- Reliability Program KPIs & GovernanceLeading and lagging reliability indicators; program review cadence; continuous improvement loop
- Reliability Improvement FacilitationLeading FMEA and RCM studies; facilitating RCFA investigations; building internal capability
- Maintenance Excellence BenchmarkingSMRP and industry benchmark frameworks; gap analysis; maturity progression planning
04
Leadership & People Engagement
The capability that makes every other practice area work — because tools without leadership don't last, and transformation without people doesn't happen.
Tier 01 · Executive
Transformation Leadership
- Expanding the View WorkshopShifting leadership perception of what top-decile performance requires; benchmarking what great looks like and what it takes to get there
- The Leader's Role in TransformationWhat the journey requires personally; time investment; visible leadership behaviors
- Executive Coaching — Performance Check-insRegular structured coaching on performance trends, leadership effectiveness, and program momentum
- Executive Team Alignment WorkshopAligning the senior team on current performance reality, transformation ambition, and shared accountability
- Change Leadership & CommunicationCrafting and delivering the transformation narrative; managing resistance at the top
- Psychological Safety in OperationsBuilding environments where teams surface problems and ideas without fear — a documented driver of reliability, safety, and improvement culture
- Engagement Action PlanningUsing engagement data to drive targeted leadership action; making engagement a business discipline
Tier 02 · Management
Operational Leadership Skills
- Coaching & Feedback FundamentalsCoaching vs. directing; structured feedback models; building a coaching habit
- Leader Standard WorkDesigning, implementing, and sustaining LSW at supervisor, manager, and director levels
- Process Confirmation & Go-and-SeeStructured floor walks; process adherence verification; observation-to-action discipline
- Daily Management Systems for LeadersTiered DMS leadership; running effective operational review meetings; escalation and response
- Managing Performance ConversationsAddressing underperformance constructively; accountability without blame; sustained follow-through
- Mentoring & Knowledge TransferStructured mentoring programs; capturing expert knowledge from experienced employees; building transfer plans before capability walks out the door
- Team Engagement & MotivationEngagement drivers in operational environments; recognition; building psychological safety at the team level
- Change Management for Operational LeadersLeading teams through change; managing resistance; sustaining momentum through the dip
Tier 03 · Shop Floor
Team Engagement
- Current State Pain-Point WorkshopsStructured sessions to surface the team's real challenges; establishing credibility for the journey
- Understanding the Transformation JourneyWhat the improvement program means for the team; what will change and what won't
- Idea Generation & Continuous Improvement CultureBuilding the habit of surfacing and acting on improvement ideas at the team level
- Problem Solving for TeamsSimple PDCA and 5-Why for frontline teams; structured problem-solving without jargon
- Safety Culture & Near-Miss ReportingPsychological safety for safety reporting; building a proactive safety culture from the floor up
- People & EngagementBuilding inclusive, high-engagement teams in operational environments; workforce participation, belonging, and team performance — recognizing that a diverse and engaged team outperforms
- Cross-Functional TeamworkWorking across shifts, departments, and functions; shared ownership of outcomes
Tier 04 · OpEx Leadership
People System Design
- Organizational Design for OEStructuring roles and teams to support a self-sustaining improvement system
- Talent Pipeline & Succession for OperationsIdentifying and developing the next generation of operational leaders
- Culture Assessment & TransformationDiagnosing organizational culture; designing interventions that move the needle
- Engagement Survey Design & Action PlanningDesigning meaningful engagement measurement; translating data into leadership action
- Internal Facilitation & Training CapabilityBuilding the internal capability to deliver workshops, training, and coaching without external support
05
AI, Agentic & Automation
Digital capability built on operational foundations — not the other way around. The curriculum ensures organizations are ready to capture the full value of intelligent automation.
Tier 01 · Executive
Digital Strategy & Investment
- AI & Automation — The Business CaseWhere AI delivers real operational value vs. hype; ROI framing; risk and readiness assessment
- Digital Foundation ReadinessWhat operational and data foundations must exist before AI investments can succeed
- Automation Strategy & SequencingPrioritizing automation investments; build vs. buy vs. partner; sequencing for sustained value
- AI Governance & Ethics in OperationsHuman oversight requirements; decision rights; responsible AI deployment in operational environments
- Industry 4.0 Leadership OrientationThe industrial technology landscape; IoT, digital twin, and agentic AI — what leaders need to know
Tier 02 · Management
Analytics & Automation Deployment
- Advanced Analytics for OperationsDescriptive, diagnostic, predictive, and prescriptive analytics — practical applications in manufacturing and logistics
- Condition-Based Monitoring AnalyticsUsing AI and analytics to process data from condition monitoring technologies — vibration, oil, thermography, ultrasound — and generate maintenance recommendations
- Demand Forecasting & Inventory OptimizationStatistical forecasting methods; ML-assisted demand planning; safety stock optimization
- Process Automation & Robotic Process AutomationIdentifying automation candidates; RPA design principles; human-in-the-loop design
- Agentic AI Workflow DesignUnderstanding agentic AI capabilities; designing workflows that leverage autonomous task execution
- Data Quality & Data GovernanceThe data foundations required for analytics and AI; master data management; data quality frameworks
- IoT & IIoT for OperationsSensor selection; connectivity architectures; integrating operational data streams
Tier 03 · Shop Floor
Working with Digital Tools
- Digital Tool OrientationUnderstanding and using digital dashboards, tablets, and connected tools on the shop floor
- Working with Automated EquipmentSafe operation alongside automated systems; human-robot collaboration; intervention protocols
- Data Entry & Quality at SourceThe importance of accurate data entry; how frontline data feeds analytics and AI systems
- Condition Monitoring with Smart SensorsReading and responding to sensor-based alerts; understanding what the data means and when to act
- AI-Assisted Decision SupportHow to use AI recommendations in daily work; when to override; feedback loop discipline
- Change Readiness for AutomationUnderstanding how automation changes roles; building confidence and engagement with new technology
Tier 04 · OpEx Leadership
Intelligent Operations Design
- Digital Twin Development & ApplicationBuilding and using digital twins for process simulation, optimization, and predictive insight
- Machine Learning for OperationsSupervised and unsupervised learning applications; model development and validation for operational use cases
- Robotics & Automation StrategyCollaborative robotics; autonomous mobile robots; automation roadmap design
- Integrated Operations Center DesignDesigning command-center environments that integrate real-time data across the full operation
- AI Program Governance & Continuous LearningSustaining AI investments; model drift management; continuous improvement of digital systems