Quality & Operational Excellence

Operational Risk in Production

Production operations face risks from equipment failure, quality escapes, supply disruption, safety incidents and human error. This course covers identifying and managing operational risks in production: risk assessment methods, process FMEA, control plans, layered process audits, contingency planning and risk reporting.

5 days Classroom or live online English

Smart Horizon Certified - Global Leadership Consultants

Take the course details with you.

Download the full standard outline: why attend, methodology, objectives, audience, competencies, the daily outline and current plans.

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Why attend

From knowledge to real-world impact.

Unmanaged production risks lead to recalls, downtime and incidents. You will learn practical tools to control them.

Workplace challenges

Professional Problems This Course Is Designed to Solve

The programme explores practical approaches to the following challenges. Results depend on how the learning is applied in your organisation.

Difficulty translating subject knowledge into practical workplace decisions.
Inconsistent approaches to the activities covered in the course outline.
Lack of a structured plan for applying and reviewing new skills.

Course methodology

How you will learn.

Risk workshops on production processes, FMEA practice, layered audit design and case studies.

Course objectives

What you'll take away.

By the end of this course, participants will be able to:

Identify operational risks in production
Assess and prioritise risks
Apply process FMEA and control plans
Implement layered process audits
Develop contingency plans
Report and monitor operational risks

Target audience

Who should attend.

This course is suitable for:

Production and operations managers
Quality engineers
Process engineers
Risk managers
Plant managers

Target competencies

Capabilities you will build.

Participants will develop competencies in:

Risk identification
FMEA
Control planning
Layered auditing
Contingency planning

Course outline

Your learning journey.

A focused, practical outline with time to explore, apply and reflect.

Day 1Production Risks

09:00–10:08Risk categories
10:08–11:00Case studies
11:00–11:30Coffee break
11:30–11:45Case studies (continued)
11:45–12:53Risk appetite
12:53–14:00Exercise

Day 2Assessment

09:00–10:08Risk assessment methods
10:08–11:00Process FMEA
11:00–11:30Coffee break
11:30–11:45Process FMEA (continued)
11:45–12:53Prioritisation
12:53–14:00Workshop

Day 3Controls

09:00–10:08Control plans
10:08–11:00Error-proofing
11:00–11:30Coffee break
11:30–11:45Error-proofing (continued)
11:45–12:53Verification
12:53–14:00Exercise

Day 4Layered Audits

09:00–10:08Audit design
10:08–11:00Frequency
11:00–11:30Coffee break
11:30–11:45Frequency (continued)
11:45–12:53Follow-up
12:53–14:00Exercise

Day 5Contingency and Reporting

09:00–10:08Contingency plans
10:08–11:00Risk reporting
11:00–11:30Coffee break
11:30–11:45Risk reporting (continued)
11:45–12:53Review
12:53–14:00Action plan

The timings provided are estimates and may vary depending on the number of participants and the discussions taking place during the sessions. They are indicative only and do not constitute a binding commitment.

Dates & venues

Find a session that works for you.

Confirmed dates accept registration requests. Tentative dates are enquiry only.

Good to know

A few things to know.

How is the course delivered?

Our classroom programmes combine facilitated discussion, case studies, exercises and reflection. The precise format will be confirmed before enrolment.

Can you deliver this programme for our team?

Yes, you can enquire about a tailored programme. Share your goals, group size and preferred dates with our learning team.

Will I receive a certificate?

Participants who complete the programme receive a Smart Horizon certificate of attendance. Smart Horizon programmes are not externally accredited and do not award a professional qualification, licence or designation. Where a course title or outline refers to a professional certification (for example, AACE International's Certified Cost Professional), the programme supports learning and preparation only; the credential itself is awarded solely by the relevant professional body under its own application and examination requirements.

What should I confirm before booking travel?

Please confirm the session, exact venue, accessibility arrangements, fees and any visa requirements with the team before arranging travel. Tentative dates are not confirmed sessions.

Keep exploring

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