Operational Excellence Strategies for Transforming Manufacturing Performance

Most operational excellence efforts optimize the metrics inside the plant, utilization, efficiency, cost, and lose sight of the customer along the way. This course goes beyond basic Lean and Six Sigma tools to help you build an integrated operational excellence framework that aligns people, process, and technology, one that works across functions, sites, and value streams.

Jeff Wilkerson, a former TI Automotive plant manager and current Caterpillar senior leader, teaches this course. He's also a certified Acceptance and Commitment Therapy practitioner. Through lectures, case studies, simulations, and guided action planning, you'll explore leader standard work, management systems, system resilience, and design thinking, then apply real tools for building the trust and accountability that make improvement stick, not just plan it.

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Who Should Attend?

Manufacturing and Process Engineers: Designing and integrating continuous improvement systems aligned with business goals
Plant Managers and Technical Leaders: Translating improvement principles into daily execution and measurable results
Operations Directors and Executives: Driving multi-site or enterprise-wide performance improvement
CI and Change Leaders: Managing large-scale transformation and culture-building initiatives

What You Will Learn

Design and implement an operational excellence framework integrating Lean, Six Sigma, and continuous improvement
Build resilient systems that manage variability and reduce systemic waste
Develop leader standard work and management systems to sustain results
Apply design thinking to operational challenges
Foster a culture of trust, engagement, and accountability
Create a tailored operational excellence action plan for their organization
Apply Kata Coaching techniques to reinforce daily improvement habits and support frontline engagement

Course Details: RA00113-E235

Day 1

Operational Excellence Foundations: Define OpEx beyond Lean/Six Sigma and explore systems thinking that aligns people, process, and technology
Resilient Systems & Variability Management: Identify systemic waste and variability drivers, then apply tools like flow mapping and bottleneck analysis to a real high-mix manufacturing case
Design Thinking for Operations: Apply design thinking to reframe a common operational challenge
Applied Systems Thinking Workshop: Map an operational system from your own organization and identify systemic barriers to excellence

Day 2

Management Systems & Leader Standard Work: Design leader standard work routines and learn Kata Coaching principles for sustaining daily improvement
Culture, Trust & Sustaining Excellence: Apply ACT-based principles to build trust, reduce resistance, and support long-term cultural change
Operational Excellence Action Plan Project: Develop a tailored action plan for your organization with peer and instructor feedback

Instructor
Jeff Wilkerson
Jeff Wilkerson is a progressive Lean leader, executive advisor, and innovative learning enthusiast with extensive experience in manufacturing and leadership. His career spans roles from machine operator to Plant Manager and later senior leadership at Caterpillar Inc., giving him a unique perspective that connects frontline realities with strategic vision. Jeff also spent time at TI Automotive in various manufacturing roles before joining Caterpillar, where he advanced through positions in operations, supply chain, engineering management, and global program leadership.

Throughout his career, Jeff has helped optimize global manufacturing operations, guided teams to implement impactful process improvements, and designed simulated work environments (SWEs) that expand real-world problem-solving capabilities and drive significant efficiency gains.

Jeff holds a Lean Master Black Belt, an MBA in Human Resources, and a BA in Leadership and Management. He has also completed advanced executive education at the MIT Sloan School of Management, focusing on Digital Business Strategy, Design Thinking, and Business Process Design. In addition, he is certified as a lay counselor in Acceptance and Commitment Therapy, reflecting his belief that sustainable operational excellence stems from prioritizing people over processes.

Today, Jeff combines his deep expertise in Lean, change management, and leadership development to help organizations achieve breakthrough results while building cultures of trust, accountability, and continuous improvement.
Program Director
James Rink

Total Credits:

CEU 1.4,

PDH 14,

Applies to these Certificates:

Manufacturing Excellence,

Quick Response Manufacturing,

Course Administration

If you are planning to attend an Interdisciplinary Professional Programs course, payment is required at the time of registration. Below are the payment options:

Pay by Credit Card

Enroll online and pay by credit card.

Search for the course on the website and then click on the Enroll Now button from the course webpage.
Enter all necessary course attendee information and payment information on the course enrollment page.
You will receive an email to confirm successful enrollment and payment.

Pay by Check

Mail in a completed registration form and check payable to UW Madison.

Fill out a registration form (found either in the back of the course brochure you received in the mail or here).
Prepare a check, made payable to UW Madison.
Mail the registration form and check to: CERC Registrations 21 N Park St, Ste 7101 Madison, WI 53715
You will receive either a mailed document or an email to confirm successful enrollment and payment.

Pay by Purchase Order

Request Purchase Order information from registration@cerc.wisc.edu
- If a fee quote is needed, contact custserv@interpro.wisc.edu first
You will receive an invoice from UW–Madison Business Services for payment, usually within 3–5 business days

Military

If using SF-182 form, please call our registration number at 608-262-2451 or email registration@cerc.wisc.edu for details and instructions.

Event Cancellation

We reserve the right to cancel a course due to insufficient enrollment or unforeseen events. If we cancel a course, participants will be notified via email or phone and will be given the option for a full refund or to transfer their registration and any fees paid to another course. We are not responsible for non-refundable plane tickets, hotel reservations, and other travel related expenses. For enrollee Course Cancellation, refer to notes on course page.

Create a custom learning experience

We can deliver this course as an on-site learning experience tailored to your organization’s specific training needs.

Operational Excellence Strategies for Transforming Manufacturing Performance

2027 and later

Who Should Attend?

What You Will Learn

Course Details: RA00113-E235

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Course Administration

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