Improving Productivity through Quality Enhancement and Cost Reduction

This DIXONTECH course equips participants with the knowledge and practical methods to enhance productivity by improving quality and reducing operational costs. The program focuses on the integration of quality management, Lean principles, and cost optimization techniques to achieve sustainable organizational performance. Participants will learn how to identify inefficiencies, eliminate waste, improve processes, and design cost-effective strategies that strengthen competitiveness while maintaining high quality standards.

TRAINING TOPICS

• Relationship Between Quality, Productivity, and Cost

• Identifying and Analyzing Productivity Gaps

• Lean Management and Waste Reduction Techniques

• Quality Improvement Tools and Root Cause Analysis

• Cost of Quality (COQ) and Cost-Benefit Models

• Process Optimization and Efficiency Improvement

• Measuring Productivity and Quality Performance Indicators

• Balancing Quality Excellence with Cost Control

• Engaging Employees in Quality and Productivity Initiatives

• Sustaining Continuous Improvement and Profitability

BY THE END OF THIS TRAINING COURSE, DELEGATES WILL BE ABLE TO:

• Understand how quality improvements drive productivity gains

• Apply Lean and cost reduction strategies effectively

• Measure and analyze productivity using KPIs and metrics

• Implement tools for process and quality improvement

• Identify hidden costs and eliminate non-value activities

• Balance cost efficiency with customer satisfaction

• Build a culture of continuous improvement and innovation

TRAINING IS TAILORED TO:

• Quality and productivity managers

• Operations and manufacturing supervisors

• Process improvement and Lean professionals

• Project and cost control managers

• Finance, supply chain, and HR professionals

• Continuous improvement teams

• Business excellence and performance consultants

TRAINING METHODOLOGY

This DIXONTECH training combines interactive discussions, case studies, and practical workshops. Participants will use real-life data to apply Lean, Six Sigma, and quality improvement techniques, and develop cost-saving initiatives without compromising performance. Through group exercises, simulations, and best practice examples, delegates will learn to drive measurable improvements in efficiency, quality, and profitability.

DAY 1

UNDERSTANDING THE LINK BETWEEN QUALITY, PRODUCTIVITY, AND COST

• The relationship between quality and productivity performance

• The cost of poor quality and inefficiency

• Measuring productivity and identifying performance gaps

• Key principles of quality-driven productivity improvement

• Balancing customer value and cost objectives

• Productivity enhancement through process excellence

• The role of leadership and employee engagement

• Case study: quality improvement leading to cost savings

DAY 2

LEAN PRINCIPLES AND WASTE ELIMINATION STRATEGIES

• The Lean mindset and its productivity impact

• Identifying the seven wastes (Muda)

• Value stream mapping for process visualization

• Streamlining workflows and reducing delays

• Techniques for optimizing resource utilization

• Continuous flow and pull-based production concepts

• Workshop: mapping and improving an inefficient process

• Case example: applying Lean to reduce operational costs

DAY 3

QUALITY IMPROVEMENT AND COST OF QUALITY (COQ) MODELS

• Understanding the components of Cost of Quality (prevention, appraisal, failure)

• Techniques for reducing the Cost of Poor Quality (COPQ)

• Root cause analysis and corrective/preventive actions (CAPA)

• Applying Six Sigma DMAIC for process improvement

• Tools: Pareto analysis, cause-effect diagram, control charts

• Linking COQ to budgeting and decision-making

• Exercise: calculating and analyzing COQ scenarios

• Workshop: designing a cost-effective quality strategy

DAY 4

PROCESS OPTIMIZATION AND PERFORMANCE MEASUREMENT

• Defining and tracking key performance indicators (KPIs)

• Methods for improving process efficiency and output

• Using data analysis and benchmarking for decision-making

• Time, motion, and workflow studies

• Balancing productivity with employee well-being

• Integrating automation and digital tools for optimization

• Case study: productivity improvement through process redesign

• Simulation: measuring performance before and after improvements

DAY 5

SUSTAINING IMPROVEMENT AND BUILDING A PRODUCTIVITY CULTURE

• Creating a culture of continuous improvement and innovation

• Empowering employees for sustained performance gains

• Change management for productivity and quality enhancement

• Establishing cross-functional improvement teams

• Monitoring and reviewing cost-saving initiatives

• Communicating results and celebrating achievements

• Workshop: designing a long-term productivity improvement roadmap

• Action plan: implementing quality and cost reduction strategies