Medical Devices Portfolio/ Value Creation Teams

Manufacturing Value Creation in Orthopaedic & Rehabilitation Products

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A sector-focused capability program designed for private equity value-creation teams and manufacturing leaders within portfolio companies producing orthopaedic supports, orthoses, rehabilitation, mobility and preventive-wellness products.

By HUKSA

Last updated September 3, 2026

Course Summary

This advanced program equips manufacturing leaders to convert operational improvement opportunities into measurable value creation across orthopaedic and rehabilitation-product manufacturing. It addresses the realities of fabric cutting, stitching, knitting, lamination, moulding, metal inserts, assembly, finishing, inspection and packaging, where high SKU variety, size variants, frequent changeovers and operator-dependent processes influence cost and quality. Participants work on live plant problems involving throughput, labour productivity, material yield, first-pass quality, rework, equipment effectiveness and automation, followed by a 90-day implementation journey.

Who Should Attend

Plant Heads and Manufacturing Leaders
Production, Industrial Engineering and Operational Excellence teams
Quality Assurance and Quality Control Leaders
Maintenance, Automation and Manufacturing Engineering teams
Supply Chain, Strategic Sourcing and Product-Development Leaders

Business Outcomes

Participants will be able to:

Increase throughput and labour productivity across operator-intensive processes.
Improve first-pass yield and reduce defects, rework, scrap and customer complaints.
Reduce changeover losses and improve manufacturing flexibility across multiple SKUs.
Prioritise automation using technical feasibility and investment-return criteria.
Build a frontline operating system for sustained problem-solving and accountability.

Course Content

Lesson Content

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Connect manufacturing performance with EBITDA, working capital and growth capacity.

Develop the plant value-driver tree across safety, quality, delivery, cost and people.

Establish baselines for throughput, conversion cost, yield and service levels.

Distinguish structural improvement from temporary production recovery.

Plant Value-Creation Diagnostic: Prioritise improvement opportunities by financial and operational impact.

Lesson Content

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Map material and information flow from raw material to finished product.

Analyse cutting, stitching, knitting, moulding, lamination, assembly and packaging processes.

Identify waiting, movement, overproduction, defects, inventory and overprocessing.

Calculate takt time, cycle time, lead time, WIP and process-cycle efficiency.

Value-Stream Mapping Lab: Build the current state and future state for a selected product family.

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Conduct work measurement and establish standard minute values.

Analyse operator cycle time, pitch time and station loading.

Use Yamazumi charts to expose bottlenecks and workload imbalance.

Improve multi-machine handling, operator allocation and line configuration.

Line-Balancing Lab: Redesign a production line to improve output per person-hour.

Lesson Content

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Define takt time, work sequence and standard WIP.

Develop visual Standard Operating Procedures and one-point lessons.

Reduce operator-to-operator and shift-to-shift variation.

Establish leader standard work and layered process audits.

Standard-Work Exercise: Create a repeatable method for a critical assembly or stitching operation.

Lesson Content

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Analyse fabric, elastic, foam, polymer, metal and packaging-material consumption.

Improve marker planning, nesting, cutting yield and offcut utilisation.

Control over-issue, scrap, rework and material substitution.

Develop should-consumption standards and material-loss trees.

Yield Improvement Lab: Quantify material losses and develop a reduction plan.

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Analyse SKU complexity across size, side, colour and support-level variants.

Separate internal and external changeover activities using SMED.

Improve tooling, fixture, thread, material and specification readiness.

Optimise campaign sizes without creating excess finished-goods inventory.

SMED Workshop: Reduce changeover time for a high-variation production process.

Lesson Content

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Measure availability, performance and quality losses through OEE.

Develop loss trees for breakdowns, minor stops, speed losses and defects.

Apply autonomous maintenance and planned-maintenance principles.

Use MTBF and MTTR to strengthen equipment-reliability decisions.

OEE Loss Analysis: Identify and prioritise the six major equipment losses.

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Connect process controls with ISO 13485-aligned quality-system requirements.

Apply process flow diagrams, PFMEA and control plans.

Establish critical-to-quality characteristics for fit, fastening, support and durability.

Use MSA and SPC for measurable product and process characteristics.

PFMEA Workshop: Assess failure modes across a selected manufacturing process.

Lesson Content

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Track FPY, rolled throughput yield, defect-per-unit and cost of poor quality.

Apply Pareto analysis to stitching, bonding, dimension, fit and finishing defects.

Use 5 Why, fishbone, containment and root-cause verification.

Link non-conformances, complaints and recurring defects with CAPA.

Defect-Elimination Clinic: Investigate a recurring quality problem and build a corrective-action plan.

Lesson Content

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Identify processes where output cannot be fully verified through subsequent inspection.

Define process parameters, acceptance criteria and validation evidence.

Strengthen lot, batch, material and operator traceability.

Manage deviation, revalidation and change-control requirements.

Traceability Exercise: Trace a product-quality issue from finished goods to process and material records.

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Identify repetitive, ergonomic, inspection and data-capture processes suitable for automation.

Evaluate cutting automation, vision inspection, poka-yoke and digital work instructions.

Apply barcode or RFID-enabled WIP and traceability controls.

Assess feasibility using quality, capacity, labour, flexibility and ROI criteria.

Automation Prioritisation Lab: Build an impact-versus-feasibility roadmap for shortlisted use cases.

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Develop daily-management routines around SQDCP metrics.

Use tiered meetings, visual boards and abnormality escalation.

Build problem-solving capability using PDCA, A3 and 8D.

Strengthen supervisor coaching, ownership and closure discipline.

Frontline Simulation: Resolve a production, quality and delivery problem through a structured daily-management review.

Lesson Content

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Consolidate productivity, quality, maintenance and automation opportunities.

Quantify expected cost, capacity, working-capital and margin impact.

Define initiative owners, milestones and implementation risks.

Develop a 30/60/90-day plant-transformation roadmap.

Operations Review Board: Present and defend a manufacturing value-creation plan.

Meet Your Instructor

Deep-domain, High Precision L&D - delivered directly by Renowned Industry Practitioners HUKSA

285 Course

300 Student

Offered by Huksa, this L&D program is led by elite industry veterans—CXOs and Functional Heads with 25+ years of deep-domain expertise. You have the flexibility to customize the curriculum, select your preferred expert, and align the program to your organization’s specific objectives. Connect with the Huksa team to explore our array of top-tier trainers available for this course!

₹ 5,00,000

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This course includes:

Lessons 13
Topics 65
Duration 3 Days
Quizzes 0
Language English

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