Quality improvement measures, Lean manufacturing principles, Problem-solving process, and Statistical Process Analysis

1.Plan-Do-Check-Act (PDCA Cycle)

  • Meaning of PDCA cycle
  • When to use PDCA cycle
  • PDCA cycle – Graphical representation
  • PDCA cycle – Explanations.

2. Brainstorming techniques

  • Introduction of Brainstorming techniques
  • Advantages of Brainstorming techniques
  • Brainstorming techniques process
  • Types of Brainstorming techniques
  • How to carry out a Brainstorming study.

3. Quality function deployment QFD

  • Meaning of QFD principles
  • Uses of QFD principles
  • Aspect of QFD
  • Benefit of QFD
  • Graphical representation of QFD principles
  • QFD methodology

4. Cause and Effect Diagram

  • Meaning of Cause and Effect diagram
  • When to use Cause and Effect diagram, How to use it?
  • Graphical representation of Cause and Effect diagram.

5. Check sheet: Tools for generating information

  • Meaning of check sheet, what is it?
  • When to use a check sheet
  • How to use a check sheet
  • Graphical representation of check sheet.

6. Flow charts: Tools for organizing information

  • Meaning of flow chart
  • When to use a flow chart
  • How to use a flow chart
  • Graphical representation of flow chart

7. Kaizen principles

  • Meaning of Kaizen principles
  • Attributes of Kaizen principles
  • Kaizen objectives
  • Kaizen benefits
  • Application of Kaizen implementation
  • Approaches for Kaizen implementation:
    1. 5S principles
    2. 8D methodology
    3. Value stream mapping (VSM)
    4. PDCA cycle
  1. 5S principles: the meaning of 5S principles, 5S acronym i.e. sort, set, shine, standardize.
  2. 8D methodology: the meaning of 8D methodology, forming of a cross-functional team in 8D methodology, Summary of the 8D process.
  3. Value stream mapping: the meaning of VSM, Usefulness of VSM, Basic steps in VSM, Graphical representation of VSM.
  4. PDCA Cycle: the meaning of PDCA cycle, when to use the PDCA cycle, PDCA cycle-Graphical representation, PDCA cycle-explanation.

(A) Lean manufacturing principles

  1. Lean manufacturing principles: Introduction
  2. Lean ideology- the idea of Lean in terms of value creation.
  3. Waste (MUDA)
  4. Major types of non-value adding waste in business
  5. Seven kinds of Waste (MUDA)
  6. Four approaches to waste elimination in an organization
  7. The focus of Lean management principles – five focus of Lean management
  8. Six objectives of Lean management
  9. Lean management tools :
    • Histogram
    • Quality control card
    • Pareto diagram
    • Correlation diagram
    • Brainstorming techniques
    • Ishikawa diagram (fishbone analysis)

Lean management tools: explanation

  1. Histogram
  • Introduction of Histogram
  • Importance of Histogram, the usefulness of histogram
  • Graphical representation of histogram and its explanation.
  1. Pareto diagram
  • Introduction of Pareto diagram
  • Importance of Pareto chart
  • The usefulness of Pareto chart
  • Graphical representation of Pareto chart and its explanation
  1. Scatter diagram
  • Introduction of Scatter diagram
  • Importance of Scatter diagram
  • The usefulness of Scatter diagram
  • Graphical representation of Scatter diagram and its explanation.
  1. Brainstorming techniques
  • Introduction of Brainstorming techniques
  • Advantage of Brainstorming techniques
  • Brainstorming techniques process
  • Types of Brainstorming techniques
  • How to carry out a Brainstorming study
  1. Cause and effect diagram techniques
  • Introduction of Cause and effect diagram
  • Importance of Cause and effect diagram
  • The usefulness of cause and effect diagram
  • Graphical representation of cause and effect diagram and its explanation
  1. General Lean management tools
  • List of general lean management tools we can come across in practice.
  1. Lean methods: identity and explanation
  • Lean management and Kaizen
  • Lean management and TPM
  • Lean management and the Pull principles
  • Lean management and Visual management
  • Lean management and Poka-Yoke
  1. Lean development in general
  2. Some practical Lean foundation tools that are common in practice:
  • Kaizen principles, PDCA cycle, JIDOKA, Poka-Yoke, Standardized work, Kanban, Genchi Genbutsu
  • 5S principles
  • Operating equipment effectiveness (OEE) measurement and development.
  1. Development of machine efficiency in Lean management:
  • Operating equipment effectiveness (OEE) measurement and development
  • Single minutes exchange of dies-SMED principles
  • Total productive maintenance TPM

15. Material flow development and design manufacturing cells:

  • Just-In-Time (JIT) principles (i.e. Pull system and Talktime explanation)
  • Cell-based production
  • Push system
  • Pull system

 Six sigma principles:

    • Definition of six sigma, what is it?
    • Six sigma indicator
    • Six sigma principles – in general
    • The Six Sigma DMAIC process: meaning
    • The Six Sigma DMADV process: meaning
    • Graphical representation and presentation of DMAIC and DMADV process.
    • Six sigma pyramid
    • Three dimensions of Six sigma principles
    • Six sigma belts: what is it? what are different kinds of six sigma belt?
    • Six sigma concepts: Key concepts of Six Sigma principles.
    • Six sigma tools in general.Six sigma principles
  • PDCA Cycle
    1. Meaning of PDCA cycle, what is it?
    2. When to use the PDCA cycle, how to use it?
    3. Graphical representation of the PDCA cycle.
    4. PDCA cycle: Explanation.

A statistical Process Capability study.

  • Introduction
  • Why / When to use process capability study?
  • Meaning of within variation Vs Overall variation
  • Graphical representation of process variation
  • Process capability Matrix
  • Capability Matrix: Pp, Ppk, Cp, Cpk, Cm, Cmk, Cg, Cgk.
  • One-sided capability Matrix
  • Acceptance criteria for capability Matrix
  • Steps to follow when conducting process capability study
  • Capability study analyzes with Minitab software explanations
  • 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 does the control chart help to avoid defects?
  • A 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.

Seven quality control tools to solve the vast majority of quality problems in practice

1) Cause and effect diagram

  1. Meaning of Cause and effect diagram
  2. When to use Cause and effect diagram, How to use it?
  3. Graphical representation of Cause and effect diagram.

2) Control charts

  1. Meaning of control charts
  2. When to use X-bar and R Control Charts
  3. How do control charts help to avoid defects
  4. A brief history of control charts
  5. Cause of variation: a. Common causes of variation
  6. Special causes of variation.
  7. Statistical Process Control –SPC- test rules. Graphical representation of the test rules.

3) Check sheet: Tools for generating information

  1. Meaning of check sheet, what is it?
  2. When to use a check sheet
  3. How to use a check sheet
  4. Graphical representation of check sheet.

4) Histogram

  1. Introduction of Histogram
  2. Importance of Histogram, Usefulness of Histogram
  3. Graphical representation of Histogram

5) Pareto analysis:

  1. Meaning of Pareto analysis
  2. The usefulness of Pareto analysis
  3. Graphical representation of Pareto chart.

6) Scatter diagram

  1. Meaning of Scatter diagram
  2. Uses of Scatter diagram
  3. Graphical representation of Scatter diagram.

7) Flow Chart: Tools for organizing information

  1. Meaning of flow chart
  2. When to use a flow chart
  3. How to use a flow chart
  4. Graphical representation of flow chart

Clients benefits: The training module will secure the clients to have the following benefits:

  • Greater productivity is enhanced
  • Smoother operations are ascertained
  • Greater flexibility and responsiveness
  • Eliminates defects (in-house and at the customer side)
  • Reduce customer complaints like 8D
  • Improve product quality
  • Improve supplier quality
  • Increased customer satisfaction
  • Reduce returns of product
  • Increase customer approval process and release of a production line within timeframe schedule

Who are the benefactors of these training modules or the target groups:

  • Plant Managers
  • Quality Managers
  • Quality Engineers
  • Production leaders
  • Process engineers
  • Quality Supervisors
  • Quality Specialist
  • Logistics
  • Technology
  • Production
  • and others categories who are interested in leaning: Seven quality tools to solve the vast majority of quality problems in the manufacturing, Continuous improvement process PDCA, Lean management principles, Statistical Process Control SPC philosophy, 5S principles, KAIZEN methodology, Six Sigma methodology etc

The training modules acquire from Hermon Quality Solutions HQS services will help you to get your career professionals smoothly and efficiently. Why not give it a try and see the difference.

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Modules for continuous improvement process