MODULES FOR PRODUCT / PROCESS IMPROVEMENT APPROACH

MODULES FOR PRODUCT / PROCESS IMPROVEMENT APPROACH

Product/Process improvements tools/techniques

1. Benchmarking principles/techniques

• Introduction
• Why benchmarking?
• Types of benchmarking?
• Outline notes to benchmarking process
• Keys to successful benchmarking principle.
• Comparison 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/techniques

• 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 definition in PFMEA
4. Recommendation and guidelines to follow in PFMEA documentation.
5. Summary steps to complete PFMEA documentation.

4) 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 techniques

• 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
3. Value Stream Mapping (VSM) in general
4. Plan-Do-Check-Act PDCA cycle

3)  MEDIC Methodology for process improvement

• 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. Plan-Do-Check-Act (PDCA) cycle

• Meaning of PDCA, when to use PDCA cycle?
• How to use PDCA cycle?
• PDCA cycle – Graphical representation and explanation.
• PDCA as a tool to analyze, understand, control and improve any process in an organization.

5. Six Sigma System principles

• Introduction
• A statistical representation of Six Sigma
• The objective of the 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 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 techniques

• Meaning of control chart
• When to use X-bar and R control chart?
• How do control charts 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 i.e. graphical representation of the test rules that can help in a practical sense.

2. EFQM Business Excellence Model/Project Excellence Model

• A chart that depicts the EFQM Business Excellence model
• Charts that depict EFQM – Radar model principles,  what are the meaning of RADAR principles.
• A chart that depicts Project Excellence model

3. Histogram techniques

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

4. Poka-Yoke methodology

• Meaning of Poka-Yoke (Mistake proofing)
• Example of Poka-Yoke
• Application of Poka-Yoke methodology
• Importance of Poka-Yoke methodology 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 the capability matrix
• Step to follow when conducting process capability study.
• Capability study analyzes with Minitab Software explanation
• Assessment of capability study after conducting the test rule – Using Minitab software

6. Statistical Process Control SPC 

• 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.
• 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.

• Another control chart that might be applicable in a practical sense:

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

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 other categories who are interested in leaning: Benchmarking principles, Process capability study, EFQM principles, Design of Experiment DOE, Continuous improvement process PDCA, Brainstorming techniques, FMEA methodology, Statistical Process Control SPC philosophy, 5S principles, KAIZEN methodology, Six Sigma methodology, the MEDIC methodology for process improvement 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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