Training Tools Index
1. Diagnostics
2. Training Case Studies
3. Functional Training
4. Wiring a business for high performance
& continuous improvement
5. The Ideas process to quickly generate
thousands of specific improvements
6. Change Management: Managing Major Performance
Improvement
1. Diagnostics & Sustainability
Audits
Determining potential savings from an area or site
Determining the Value Drivers of a Business
High Performance Diagnostics - Operations
High Performance Diagnostics - Maintenance
High Performance Diagnostics - Planned Shuts
High Performance Diagnostics - Safety
High Performance Diagnostics - Cost Management
High Performance Diagnostics - Talent Management
- Targetted Sustainability Audits
- Action Tracker Audit
- Idea Tracking Audit
- Variance Process
- KPI Management Process
- Checklists
- Shut Management
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2. Training Case Studies
Mining
Mineral processing
Manufacturing
Pulp & paper
Telecommunications
Retailing
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3. Functional Training
Capex process
- ROCx - Rigorous Optimisation of Capex for large Projects
- The Business Case - Maximising Value and Minimising
Risk
- The Macro Design - Optimising Capital against the
Business Case
- The Detailed Design - the Remaining Layer of Savings
- Creating an ongoing, rigorous capital process in the organisation
- Cost reduction, Procurement & Contractor Management
- Usage Reduction
- Toolkit for Usage Reduction
- Optimising Chemical & Reagent usage and cost
- Raw Materials - optimising the value, reducing waste
- Systematic Reduction in Consumable Costs
- Reducing the Costs of Power, Energy, Fuel, Water
- Transport & Logistics (usage, efficiencies, negotiation)
- Maintenance (getting the right mix of insource &
outsource)
- Maintenance: reducing costs while increasing plant
availability
- Reducing the costs of Mining Equipment (Tyres, Parts)
- Contract Labour (Cleaning, Industrial Cleaning, Labour
Hire, Casual Labour)
- External Repairs, Maintenance Parts & Labour
- Yield & Waste Reduction
- Tackling Direct Labour Costs without damaging the
business
- Cement, Silica, Vent Bags, Shot, Ground Support,
Grinding Media
- Telecommunications, Stationery & Office Supplies
- Professional Services
- PPE (Protective and Safety Equipment) - getting the
most for your money
- Labour Reductions - having a consistent message
- Cost reduction approach in support departments
- Cost Management
- Ensuring the right accountabilities and KPIs for
cost
- Cost reporting and reviewing - establishing good
reviews
- How to manage costs in your area (tips, tricks, behaviours)
- Procurement
- Overview of Procurement Approaches
- Case Studies of Different Types of Situations
- Total Cost of Ownership
- Defining Usage Requirements
- Reducing Usage (see cost reduction)
- Determining the Terms You Need
- Current Relative Bargaining Positions
- Improving your Next Best Alternative: tilting the
tables
- Reverse Engineering Supplier Costs
- Determining the Best Process for "Negotiating" on
Price
- Preparing for the Process
- Negotiation Training
- Contract KPIs and Incentives - KPIs that really work
- Basic Legal Training for Procurement Teams
- Insource/Outsource Frameworks and Case Studies
- Bankable Costdowns
- How to Review Procurement Teams
- Budgetting - how to actively link this to cost reduction
- Expense forecasting
- Contractor Management
- Overview of Contractor Management
- Contractor Management Case Studies
- Systematic Usage Reduction
- Overview of Contractor Management Systems
- Assigning Accountabilities & Developing Targets
- Reviewing Authorisation Levels
- Gate/site access control
- Management of Contractor Time/Efficiency
- Using KPIs and terms to Align Contractor Incentives
- Budgetting and Controls
- Contract Owners, their Role, Reviews etc.
- Load Smoothing etc. (understanding supplier's
cost drivers)
- Controlling Variations
- Reviewing Contractors/Scorecards etc.
Increasing volumes and quality
- How to Systematically debottleneck your operation
- Case Study - debottlenecking sinter plant
- Case Studies - debottlenecking metal processor
- Case Studies - debottlenecking mine ops
- Quality Improvement - case studies and tools
Maintenance
- Maintenance Case Studies (downtime, costs)
- Frameworks and Tools for Reducing Maintenance Costs
- Frameworks and Tools for Reducing Downtime
- Maintenance KPIs, Accountabilities, Role Clarities, Typical
Diaries
- Maintenance Reporting and Reviews
- Specific Topics
- 5 Whys - continuous improvement to reduce downtime/costs
- extensive worked examples
- Improving Recording History
- Rotables Tracking
- Spares Management, Criticality Analysis
- Pump Notification, Pump Management
- Checklists
- Lubrication
- Scopes of Work
- Using SAP for maintenance planning, scheduling etc.
- Condition-based monitoring and reporting
- Carrying out an equipment-based Criticality Analysis
- How to do Equipment-based Maintenance Strategies
- Process for Feeding back to Operators on Notifications
Planned shuts
- Planned Shuts Diagnostic and Scorecards
- Measuring Shut Performance
- Shut Management Frameworks (Frequency, Duration, Management)
- Drivers for Reducing Shut Time & Cost
- Case Studies of Shut Work (results, approach)
- Reducing Critical Paths - systematic approach
- Reducing Shut Frequency & Extending Campaign Life
- Shut Management & Systems
- Shut Procedures
- Frameworks for the key stages in a Shut (plan, execute,
review)
- Roles, KPIs and Accountabilities
- Meetings that Drive Successful Shuts
- Reporting & Reviewing at each Stage in a Shut
- Managing Tasks in a Shutdown
- Managing Safety on Major Shutdowns
- Shut Task Management (Job Planning Sheets, Tradesperson
jobsheets, Exception Management, Managing Variations)
- Shutdown Manuals & Procedures
Safety
- Benchmarking & write ups on site visits
- Safety Audits, diagnostics etc
- Case Studies of Our Safety Improvement Work
- Key concepts around safety and safety management
- Safety Training for PIP hires, exam etc.
- Understanding Safety Programs (PASS, STOP, Safe Act Observations.)
- Topic Trainings
- Risk (risk assessment, Hazop, Job Safety Analysis,
Safety Planning, Critical Task Analysis)
- Duty Of Care
- Induction, Visitor Inductions etc.
- Permit to Work etc.
- Job Safety Analysis - what they are, how to do
- Safe Act Observations - what they are, how to do
- Near Miss Reporting - why, what they are, how to do
- Incident Notification and Investigation, ICAM &
ICAM audits
- Root Cause Analysis in Safety
- Safety Management
- KPIs - leading and Lagging.
- Accountabilities
- Reporting and Reviewing Safety to Drive Improvements
- From safety wiring framework to accountabilities to
safety scorecards
People management
- Simple Ways to Open Up Transparent Communication Up &
Down the Organisation
- KPIs, Acccountability, Role Clarity, Diary Analysis,
Ideal diaries by role
- Talent Management, Successsion Planning
- Performance Coaching & How to Give Productive Feedback
- Performance Check-in
- Performance counselling & Discipline Management
- Recruiting process - Hiring for talent
- Incentive schemes - what really works when you implement
it
- Conflict resolution
- Employee Relations and Industrial Relations
- Managing Absenteeism
- Overtime Management
- Career Management
- Organisational Review
Sales & Marketing
- Industrial Marketing Frameworks and Case Studies
- Sales Force Effectiveness Frameworks and Case Studies
- KPIs, Acccountability, Role & Typical Diaries
- Typical Sales Reports, KPI tracking, Analysis of 'Controllables'
etc
- Holding Sales Reviews which Drive Improvement
Statistical Tools
- Quick guide to SPC (Statistical Process Control)
- Sampling Principles
- Cusum - what is it, how to use it
Strategy
- Introduction to Major Strategic Frameworks
- Game theory for procurement
Supply chain, logistics & inventory
- Supply chain management
- Raw materials optimisation
Financial Concepts
- Transfer Pricing
- Valuation
- NPV/Payback/IRR - valuing projects or decisions
- Accounting for Operations Managers
- Managing Cost in You Operation
- Carrying out Due Diligence
Environmental
- Case Studies of our Environmental Work Reducing Emissions,
Waste, Utilising Waste Product etc.
- Environmental Strategies
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4. Wiring a business for high performance
& continuous improvement
Leading for high performance
- Symbolic Leadership
- How to combine the best of Relationship-based cultures
and Performance-based cultures
- How to Manage by Walking Around
- What does Holding to Account Mean and how to do it?
- What does a High Performance Company Look like?
- The Manager's Role is creating and maintaining a High
Performance Culture
- Articulating the End Game until it becomes a reality
- The HighPerformance Organisation - putting all the pieces
together
Driving Performance Through Reviews
- Key ingredients of Reviews
- How to run valuable reviews
- The crucial reviews for your organisation and what they
should look like
- Engaging the GM/VP through the review process
- Weekly site and area reviews - the ingredients for success
- Shift by shift review - overview of key ingredients, examples
- Morning meetings - driving improvement
- Getting the most out of your Shift Handovers
Using Targets to gain Continuous Improvement
- What makes a good target
- The art of target setting
- The monthly target setting process
Clarifying Accountabilities
- Determining the KPIs for a business
- What makes a good KPI
- How to assign accountabilities (what works)
- Ensuring role clarity
- Clarifying what's in a role (diary management)
- How best to cascade KPIs
- Reviewing KPIs
Managing Efficiently - creating the time to lead improvement
- Prioritising - ensuring the focus is on value
- Time Management
- Diary Management
- Meeting Management
Operating Disciplines - ensuring the operation is running
correctly
- Checklists to ensure minimum standards - what works,
what doesn't
- Operating Procedures to ensure repeatability
- Response Plans to improve quality of response to variances
- Using Variance Reports to drive Continuous Improvement
- Using Non Conformance Reports to maintain minimum standards
- Shopfloor problem solving (5 Whys and Root Cause Analysis)
- Shift handover procedures
- Change Control Forms and approaches
- SPC to Manage Inherent Variability
- SPC - introduction to the concepts of Variability Reduction
- Callibration
- Operations Statistics (cusum, sampling, in control &
capable, 6 sigma.)
- Sustainability Audits (see Diagnostics)
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5. The Ideas process to quickly
generate thousands of specific improvements
Overview of the Idea Pipeline
Action trackers & activity management system
Idea identification phase
- Developing Value Driver Trees ("Where's the Money?")
- How to generate quality ideas
- Root cause problem solving
- 6 sigma and other problem-solving tools (which tool for
which problem)
- How to prioritise ideas (and effort)
- Rapid quantification of Ideas
- Writing up Ideas to ensure quality input and critique
- Writing excellent workplans
- How to gain Agreement and Approval for ideas
Idea implementation phase
- Project Management Concepts
- Tracking implementation
- Implementation Facilitator Training
- Implementation Progress Reviews - How To Guide
Idea 'Cashflowing' & Lock-in Phases
- How to Validate Ideas (Validators Guide)
- Preparing for Validation (Idea Owner)
- Ongoing Audit of key Ideas
Idea Owner training
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6. Change Management:
Managing Major Performance Improvement
Overview of the PIP process
PIP project design
Phases of a turnaround
Project logistics
Project kickoff
PIP Business Coaches - Relationships
Team roles
- Role of the Business Coach
- Role of the Site Team Leader
Team effectiveness
Team workplans
Implementation management
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