Course 1 of 8Short Course

Process Optimisation Fundamentals

Build practical capability to assess process performance, identify bottlenecks and inefficiencies, investigate root causes and develop structured optimisation actions.

About the Course

Process Optimisation Fundamentals provides a practical introduction to the principles and methods used to improve process performance, efficiency and operational effectiveness.

Participants learn how to assess current performance, identify bottlenecks and inefficiencies, interpret operational data, investigate root causes, evaluate improvement opportunities and develop structured optimisation actions.

The course emphasises practical application, data-informed decision-making and continuous improvement across process-based environments.

What You Will Learn

Explain the fundamental principles of process optimisation and performance improvement.
Identify and interpret key process-performance indicators.
Map processes and establish appropriate performance baselines.
Analyse operational data to identify variability and performance gaps.
Apply structured root-cause analysis techniques.
Identify bottlenecks, constraints and improvement opportunities.
Evaluate optimisation opportunities based on impact, feasibility, cost and risk.
Prioritise improvement actions using structured decision-making tools.
Develop a practical process-optimisation action plan.
Establish appropriate KPIs and monitoring approaches to sustain improvements.

Course Curriculum

5 modules · ~15 h indicative total

Process Performance Fundamentals~2.5 h8 topics

Process optimisation principles
Productivity and efficiency
Throughput and yield
Capacity utilisation
Quality performance
Resource intensity
Process baselines
KPI selection

Process Mapping and Performance Analysis~3 h8 topics

Process boundaries
Inputs and outputs
Process mapping
Critical process variables
Operational data sources
Baseline development
Trend interpretation
Performance-gap identification

Bottlenecks, Variability and Root-Cause Analysis~3 h8 topics

Bottleneck identification
Capacity constraints
Process variability
Utility and equipment limitations
5 Whys
Cause-and-effect analysis
Pareto analysis
Root-cause verification

Optimisation Opportunity Development~3 h9 topics

Improvement opportunity generation
Operating-parameter optimisation
Yield improvement
Loss reduction
Utility reduction
Technical feasibility
Operational impact
Cost and risk
Opportunity prioritisation

Implementation and Continuous Improvement~3.5 h8 topics

Action planning
Performance targets
KPI monitoring
Implementation responsibilities
Performance dashboards
Standardisation
Continuous-improvement cycles
Preventing performance regression

Who Should Attend

Process engineersChemical engineersProduction and manufacturing engineersOperations engineersPlant and facility engineersMaintenance and reliability professionalsContinuous-improvement and operational-excellence personnelTechnical supervisors and team leadersGraduate engineers entering process-based industriesTechnical professionals responsible for efficiency, productivity or process performance

Prerequisites

Basic familiarity with engineering, manufacturing, production or process-based operations
General familiarity with operational data or performance indicators
Basic numerical and problem-solving skills

No prior formal training in process optimisation is required.

Practical Learning

Participants apply the concepts through structured exercises rather than relying on lectures alone.

Process Performance Review

Identify appropriate KPIs for a simplified process.

Process Mapping Exercise

Map inputs, outputs, critical variables and potential losses.

Operational Data Interpretation

Review process trends and identify abnormal performance.

Root-Cause Analysis Exercise

Apply 5 Whys, cause-and-effect analysis and prioritisation tools.

Optimisation Prioritisation Exercise

Rank improvement opportunities according to impact, feasibility, cost and risk.

Applied Case Study

The course concludes with an integrated process-improvement scenario involving reduced throughput, increased resource or utility consumption, declining yield, recurring downtime, process variability or quality losses.

Applied workflow

Performance diagnosis
Root-cause assessment
Optimisation proposal
KPI monitoring plan

Resources Included

Representative resources for the website (the full internal toolkit may be broader):

Process Performance Assessment Template

Process Mapping Worksheet

KPI Selection Guide

Root-Cause Analysis Worksheet

Optimisation Opportunity Register

Improvement Prioritisation Matrix

What You Will Gain

Develop a structured and practical approach to analysing process performance, diagnosing inefficiencies and translating findings into evidence-based optimisation actions.

Stronger process-performance assessment capability
Practical root-cause analysis skills
Improved ability to identify bottlenecks and constraints
Framework for evaluating improvement opportunities
Practical tools for prioritising actions
Structured approach to monitoring and sustaining improvements

Industry Applications

ManufacturingChemicalsFood and beverageWater and wastewaterMining and mineral processingEnergyOil and gasUtilitiesPharmaceuticalsMaterials processing

Delivery Options

Live Virtual Training

Interactive instructor-led delivery incorporating exercises, analysis and discussion.

Instructor-Led Classroom Training

Face-to-face delivery with practical activities, case work and direct instructor interaction.

Corporate Cohorts

Organisation-specific delivery with examples and scenarios adapted to relevant operational or technical contexts where appropriate.

Blended Delivery

A combination of instructor-led sessions and structured independent activities or applied project work.