MODULES FOR PRODUCT / PROCESS IMPROVEMENT APPROACH

Product/Process improvements tools/techniques

1. 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.

2. Brainstorming principles

• Introduction
• Brainstorming process
• Guidelines on how to use brainstorming approach in your study.
• Types of brainstorming principles.

3. Process Failure Mode Effect Analysis PFMEA

• Introduction of PFMEA
• PFMEA documentation outlook
• Completion of PFMEA documentation using step 1-9.
• PFMEA definition of terms:

1. Analyzing of PFMEA documentation
2. Pareto chart in PFMEA documentation
3. An example of rating definiition in PFMEA
4. Recommendation and guidelines to follow in PFMEA documentation.
5. Summary steps to complete PFMEA documentation.
6. 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.

1. 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.

2. 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:

1. 5S principles
2. 8D methodology in details
3. Value Stream Mapping (VSM) in general
4. PDCA cycle in details
5. 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.

4. 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.

5. 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.

1. 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.

2. 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

3. Histogram

• Introduction of Histogram
• Importance of Histogram, usefulness of Histogram
• Graphical representation of Histogram and its explanation.

4. 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.

5. 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

6. 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)

1. Select the process characteristics
2. Establish the sampling plan and rational subgroup size
3. Gather data/ enter into Minitab software
4. Establish the overall mean and control limit.

• Calculation of control limits of each of control chart
• Types of control chart:

1. Attribute and variable control chart in general
2. Mean range base X control chart.

• Other control chart that might be applicable in practical sense:

1. Standard error based X chart
2. R-chart
3. Moving range e.t.c.