Course Details

Business Continuity Management for Manufacturing and Industrial Plants Training Course

Introduction

In the intricate world of manufacturing and industrial operations, maintaining uninterrupted production, safeguarding equipment, ensuring worker safety, and fulfilling supply chain commitments are paramount. A disruption – whether from equipment failure, power outages, natural disasters, cyberattacks on operational technology (OT), or supply chain breakdowns – can lead to immediate production halts, significant financial losses, damage to brand reputation, and even critical safety hazards. Our intensive 10-day "Business Continuity Management for Manufacturing and Industrial Plants" training course is meticulously designed to equip plant managers, operations directors, engineers, safety officers, and supply chain professionals with the specialized knowledge and practical frameworks required to develop, implement, and maintain robust Business Continuity Management (BCM) programs tailored to the unique complexities and high-stakes environment of industrial and manufacturing facilities.

This comprehensive program delves into the specific challenges of ensuring continuous production lines, managing critical operational technology (SCADA, DCS), protecting hazardous materials, securing complex supply chains for raw materials and finished goods, and prioritizing worker safety during a disruption. Participants will gain in-depth understanding of how to conduct a manufacturing-specific Business Impact Analysis, identify critical production processes, design resilient operational models, and establish effective incident response protocols for industrial emergencies. By the end of this specialized training, you will be proficient in establishing a resilient BCM framework that not only safeguards manufacturing operations and assets but also ensures worker safety, upholds environmental responsibility, and maintains market competitiveness in the face of any unforeseen challenge.

Duration

10 Days

Target Audience

The "Business Continuity Management for Manufacturing and Industrial Plants" training course is essential for a wide range of professionals within manufacturing facilities, industrial plants, and production environments who are responsible for operations, safety, maintenance, and supply chain integrity. This includes:

• Plant Managers and Operations Directors: Accountable for overall production continuity and safety.
• Production and Line Managers: Directly responsible for maintaining output and efficiency.
• Maintenance and Engineering Teams: Focused on equipment reliability and recovery.
• Health, Safety, and Environment (HSE) Managers: Integrating safety and environmental protection into continuity plans.
• Supply Chain and Procurement Managers: Ensuring continuity of raw materials, components, and finished goods distribution.
• IT and OT (Operational Technology) Managers: Responsible for the resilience of control systems, SCADA, and production IT.
• Business Continuity Managers/Coordinators: Within manufacturing companies, tasked with BCM program development.
• Risk Management Professionals: Specializing in operational, technological, and safety risks in industrial settings.
• Quality Control/Assurance Managers: Ensuring product integrity during and after disruptions.
• Warehouse and Logistics Managers: Overseeing inventory and distribution continuity.

Course Objectives

Upon successful completion of the "Business Continuity Management for Manufacturing and Industrial Plants" training course, participants will be able to:

• Understand the unique threats, operational interdependencies, and safety considerations for BCM in manufacturing and industrial plants.
• Interpret and apply relevant industry standards, regulations (e.g., OSHA, local environmental laws), and best practices for industrial continuity.
• Conduct a manufacturing-specific Business Impact Analysis (BIA) to prioritize critical production processes and assets.
• Define appropriate Recovery Time Objectives (RTOs) and Recovery Point Objectives (RPOs) for production lines, equipment, and data.
• Develop robust continuity strategies tailored for plant operations, operational technology, and specialized equipment.
• Implement effective incident response and crisis management protocols for industrial emergencies (e.g., equipment failure, hazardous material spills).
• Understand and manage complex supply chain disruptions specific to manufacturing, including raw material and component shortages.
• Plan and execute realistic exercises and drills to validate the effectiveness of industrial continuity plans, emphasizing safety.
• Ensure the BCM program aligns with worker safety regulations, environmental protection, and quality control standards.
• Contribute significantly to maintaining production continuity, safeguarding personnel, and protecting the environment during disruptive events.

Course Modules

Module 1: Unique Context of BCM in Manufacturing & Industrial Plants

• Defining BCM in an industrial setting: focus on production lines, equipment, worker safety, and environmental protection.
• Understanding unique threats: equipment breakdown, power fluctuations, cyberattacks on OT/ICS, hazardous material incidents, labor disputes.
• The impact of disruptions: production halts, financial losses, regulatory fines, reputational damage, safety risks.
• Overview of key industry-specific BCM drivers and compliance requirements (e.g., ISO standards, local health and safety regulations).
• Challenges unique to manufacturing BCM: complex machinery, just-in-time logistics, specialized skills.

Module 2: Governance, Policy & Integrated Risk Management

• Establishing a robust BCM governance framework suitable for industrial organizations.
• Developing BCM policies and directives that integrate with existing safety, quality, and environmental management systems.
• Defining clear roles, responsibilities, and accountability for BCM from plant floor to executive leadership.
• Ensuring leadership commitment and allocation of resources for continuity initiatives.
• Integrating BCM with operational risk management, quality control, and HSE frameworks.

Module 3: Business Impact Analysis (BIA) for Production Processes

• Conducting a BIA focused on critical production lines, assembly processes, and essential machinery.
• Identifying the minimum viable production levels during a disruption.
• Determining RTOs and RPOs for equipment, production output, and key operational data.
• Assessing the impact of downtime on supply chain commitments, customer orders, and financial targets.
• Mapping operational interdependencies within the plant (e.g., utilities, specific equipment, control systems).

Module 4: Operational Technology (OT) & IT Disaster Recovery in Manufacturing

• Strategies for ensuring the resilience of SCADA, DCS, PLCs, and other industrial control systems (ICS).
• Data backup, replication, and restoration for process control data, production logs, and equipment settings.
• Cybersecurity measures and recovery from cyberattacks targeting OT/ICS environments.
• Ensuring continuity of IT systems supporting manufacturing (e.g., ERP, MES, inventory management).
• Segregation of IT and OT networks for enhanced security and resilience.

Module 5: Continuity Strategies for Production & Equipment

• Strategies for maintaining critical production processes (e.g., redundant lines, alternative machines, manual workarounds).
• Contingency plans for specialized machinery failure and long lead-time equipment.
• Developing agreements for shared production capacity or outsourcing with other manufacturers.
• Maintaining critical spares inventory and access to specialized maintenance personnel.
• Plans for phased recovery and ramp-up of production post-disruption.

Module 6: Workforce & Personnel Continuity in Industrial Settings

• Strategies for ensuring the availability of essential operational and technical personnel (e.g., skilled technicians, engineers).
• Cross-training programs for critical roles on the factory floor and in control rooms.
• Emergency communication plans for shift workers and remote sites.
• Protocols for worker safety during emergency response and recovery operations.
• Addressing labor shortages and specialized skill gaps during prolonged disruptions.

Module 7: Supply Chain Continuity for Raw Materials & Components

• Identifying critical raw materials, components, and sub-assemblies.
• Strategies for diversifying suppliers, dual-sourcing, and maintaining safety stock levels.
• Developing contractual agreements with suppliers that include BCM clauses and emergency delivery options.
• Managing logistics for inbound materials and outbound finished goods during disruptions.
• Addressing transportation bottlenecks and port closures affecting industrial supply chains.

Module 8: Hazardous Materials & Environmental Continuity

• Specific plans for managing hazardous materials, waste, and by-products during a disruption.
• Protocols for containment, environmental protection, and emergency spill response.
• Ensuring compliance with environmental regulations during and after an incident.
• Strategies for maintaining utility services (power, water, wastewater treatment) to prevent environmental impact.
• Liaising with environmental protection agencies and local authorities.

Module 9: Incident Response & Crisis Management in Plants

• Developing a specific incident response plan for industrial emergencies (e.g., fire, explosion, major equipment failure, hazardous leak).
• Establishing a Plant Emergency Response Team and an Incident Command System (ICS) structure.
• Protocols for emergency shutdown, evacuation, and personnel accountability.
• Coordination with local emergency services (fire, police, hazmat).
• Internal and external communication strategies during industrial incidents.

Module 10: Testing, Maintenance & Continuous Improvement

• Designing and conducting rigorous exercises for industrial continuity plans (e.g., simulated power outage, equipment failure drills).
• Involving production, maintenance, IT/OT, and HSE teams in drills.
• Evaluating exercise performance against RTOs, safety protocols, and production output targets.
• Documenting lessons learned, identifying operational vulnerabilities, and implementing corrective actions.
• Establishing a robust maintenance schedule for BCM plans, equipment, and control systems, integrated with regular plant maintenance.

CERTIFICATION

• Upon successful completion of this training, participants will be issued with Macskills Training and Development Institute Certificate

TRAINING VENUE

• Training will be held at Macskills Training Centre. We also tailor make the training upon request at different locations across the world.

AIRPORT PICK UP AND ACCOMMODATION

• Airport pick up and accommodation is arranged upon request

TERMS OF PAYMENT

• Payment should be made to Macskills Development Institute bank account before the start of the training and receipts sent to info@macskillsdevelopment.com