MODULES FOR PRODUCT / PROCESS IMPROVEMENT APPROACH
Product/Process improvements tools/techniques
- Benchmarking principles
- Introduction
- Why benchmarking?
- Types of benchmarking?
- Outline notes to benchmarking process
- Keys to successful benchmarking principle.
- Comparisim between without benchmarking and with benchmarking process in the practical sense.
- Hints on the critical steps of the benchmarking process
- Steps involved in benchmarking for Six sigma practitioners.
- General essential steps to successful benchmarking techniques in Automotive industries.
- Benchmarking principles flow model.
- Brainstorming principles
- Introduction
- Brainstorming process
- Guidelines on how to use brainstorming approach in your study.
- Types of brainstorming principles.
- Process Failure Mode Effect Analysis PFMEA
- Introduction of PFMEA
- PFMEA documentation outlook
- Completion of PFMEA documentation using step 1-9.
- PFMEA definition of terms:
- Analyzing of PFMEA documentation
- Pareto chart in PFMEA documentation
- An example of rating definiition in PFMEA
- Recommendation and guidelines to follow in PFMEA documentation.
- Summary steps to complete PFMEA documentation.
- Quality function deployment (QFD)
- Meaning of QFD principles
- Uses of QFD principles
- Aspect of QFD
- Benefit of QFD
- QFD methodology
- Graphical representation of QFD principles
- QFD Summary
Product/Process improvement tools/techniques 2.
- Design of Experiment DOE
- Introduction
- Preparation of DOE
- Components of Experimental design
- Purpose of experimentation
- Design guidelines
- Design process
- One factor experiment, meaning and how it is applicable in practice.
- Multi factor experiment, meaning and how it is applicable in practice.
- Kaizen methodology
- Meaning of Kaizen principles
- Attributes of Kaizen principles
- Kaizen objectives
- Kaizen benefits
- Application of Kaizen implementation in an organization.
- Approaches for Kaizen implementation in an organization:
- 5S principles
- 8D methodology in details
- Value Stream Mapping (VSM) in general
- PDCA cycle in details
- MEDIC methodology:
- What is MEDIC methodology
- How is it use/applicable for process improvement.
- When to use MEDIC methodology
- Steps to process improvement in MEDIC methodology.
- PDCA cycle
- Meaning of PDCA, when to use PDCA cycle?
- How to use PDCA cycle?
- PDCA cycle – Graphical representation and explanation.
- PDCA as tool to analyze, understand, control and improve any process in an organization.
- Six Sigma System principles
- Introduction
- Statistical representation of Six Sigma
- Objective of Six Sigma methodology
- The Six Sigma DMAIC process – meaning, uses, application.
- The Six Sigma DMADV process – meaning, uses, application.
- Six Sigma concept
- Six Sigma tools to focus or concentrate on.
- Six Sigma belt.
- Four phases of improvement using of key tools
- Six Sigma and Lean principles
- Road map to Six Sigma principles
- How important Six Sigma in Automotive industries
- Graphical representation of DMAIC and DMADV process.
Product/Process improvement tools/techniques 3.
- Control Chart
- Meaning of control chart
- When to use X-bar and R control chart?
- How do control charts helps to avoid defects?
- Brief history of Control chart
- Cause of variation: a. common cause of variation b.special cause of variation
- Statistical Process Control – SPC- test rules i.e. graphical representation of the test rules that can help in practical sense.
- EFQM Business Excellence Model/Project Excellence Model
- Chart that depict EFQM Business Excellence model
- Charts that depict EFQM – Radar model principles, what are the meaning of RADAR principles.
- Chart that depict Project Excellence model
- Histogram
- Introduction of Histogram
- Importance of Histogram, usefulness of Histogram
- Graphical representation of Histogram and its explanation.
- Poka-Yoke device
- Meaning of Poka-Yoke (Mistake proofing)
- Example of Poka-Yoke
- Application of Poka-Yoke device
- Importance of Poka-Yoke device in production.
- Process Capability study in general
- Introduction
- Why/When to use it?
- Meaning of within variation Vs Overall variation
- Graphical representation of process variation
- Process Capability Matrix
- Capability Matrix: Pp, Cp, Ppk, Cpk, Cm, Cmk, Cg, Cgk.
- One sided capability Matrix
- Acceptance criteria for capability matrix
- Step to follow when conducting process capability study.
- Capability study analyze with Minitab Software explanation
- Assessment of capability study after conducting the test rule – Using Minitab software
- Statistical Process Control SPC in general.
- Meaning of SPC philosophy, application of SPC principles and its originator.
- Control chart – meaning focus on variation.
- How do control chart help to avoid defects?
- Brief history of control chart
- Cause of variation: a. common cause of variation b. special cause of variation
- Statistical Process Control – SPC – test rules, graphical representation.
- Steps in constructing an Average and Range chart (X bar and R)
- Select the process characteristics
- Establish the sampling plan and rational subgroup size
- Gather data/ enter into Minitab software
- Establish the overall mean and control limit.
- Calculation of control limits of each of control chart
- Types of control chart:
- Attribute and variable control chart in general
- Mean range base X control chart.
- Other control chart that might be applicable in practical sense:
- Standard error based X chart
- R-chart
- Moving range e.t.c.