Quality

New 6 Core Tools

  • History of APQP
  • Difinition of APQP
  • Types of Core tools
  • Various organizational road blocks
  • Importance of APQP
  • PDCA Cycle in APQP
  • Input and output of APQP in evry stages/Phases
  • Benefits of APQP
  • APQP – Phases Steps
  • Step 0 – Define Scope
  • Step 1 – Plane & Define Programme
  • Step 2 – Product design & development
  • Step 3 – Process Design & Development
  • Step 4 – Product & Process Validation
  • Step 5 – Feedback Assessment & Corrective Action

Key Changes in APQP 3rd edition and Discussion on
  1. Leadership Engagement and accountability
  2. “Phase 0” addition of sourcing, high risk supplier selection and evaluation.
  3. Phase Gates & Gate reviews
  4. Gate review deliverable checklists
  5. Project risk mitigation
  6. Program Metrics.
Advanced Product Quality Planning (APQP) Output :
  • Effective planning strategy
  • Delivery performance as per Customer Expectations
  • Enhancement of Customer Satisfaction
  • Effective Use of Lessons Learned and Best Practices

Failure Mode and Effects Analysis (FMEA) Output :
  • Eliminate or reduce failures
  • Starting with the highest priority ones
  • Documents current knowledge and actions about the risks of failures
  • FMEA is used during design to prevent failures.

Control Plan (CP) Output :
  • Create effective Control Plans
  • Ensure process consistency
  • Improve product quality
  • Respond to deviations efficiently

Measurement System Analysis (MSA) Output :
  • Improved Decision Making
  • Risk Management
  • To avoid type 1 and type 2 error
  • Producing a consistent product in manufacturing

Statistical Process Control (SPC) Output :
  • Improved Product Quality
  • Problem Solving
  • Continuous Improvement
  • Statistical Process Control (SPC)
  • Risk Mitigation
  • Decision making

Production Part Approval Process (PPAP) Output :
  • When to Notify customer
  • When PPAP has to be submit
  • Retention and Submission requirement of PPAP
  • What are all the PPAP approval documents
  • Verification of process and product parameter
 

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7QC

  • Introduction to Quality Control
  • Histogram
  • Cause & Effect Diagram
  • Check Sheets
  • Pareto Diagram
  • Graphs or Flow Chart or Run Chart
  • Control Chart
  • Scatter Diagram
  • Q&A
  • How to utilize the seven quality control tools and methodologies
  • The problem-solving process and the PDCA method.
  • Learn how to analyze and understand data from seven quality control instruments.

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MSA (Measurement System Analysis)

What is MSA?
  • This course introduces Measurement Systems Analysis (MSA) and the methodologies used to examine both attribute and variable measurement systems as described in the Measurement Systems Analysis reference handbook.

Who should attend?

  • Anyone involved in gauge design, process measurement, and early process studies to support new product and process introduction who is supporting the Advanced Product Quality Planning (APQP) process.

 

  • Measurement System Analysis (MSA) Terms
  • MSA Studies
  • Sources of Variation
  • Repeatability and Reproducibility
  • Accuracy and Precision
  • Gage Repeatability & Reproducibility (GR&R)
  • Completing a GR&R Study
  • GR&R Planning Considerations
  • Attribute Agreement Analysis
  • Q&A
  • To determine whether a measuring system is suitable for its intended application.
  • Examine variable and attribute gauges.
  • Carry out stability, bias, and linearity studies.
  • Recognize the various methodologies used for attribute and variable measurement systems.
  • Recognize the origins of measuring system inaccuracy.

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FMEA (Failure Mode And Effect Analysis)

What is FMEA?

  • A stitch in time saves nine,FMEA(Failure Mode and Effect analysis) is used to recognize the problems and solve them using some effective techniques.

Who should attend?

  • Those who work on the development or specification of products, methods, or services.
  •  Those in charge of business or process improvement management
  • Managers who want to learn about the benefits of FMEA before implementing it in their firm will attend.
  • Team members that provide assistance.

 

  • FMEA Process Overview
  • FMEA Methodology
  • PFMEA & DFMEA
  • FMEA Linkage and Collaboration
  • Practical application of the FMEA technique
  • Q&A
  • To Conduct FMEAs for both the product and the process.
  • To Contribute to the creation of a Design and Process FMEA.
  • Define risk and the degrees of risk that must be mitigated.
  • Select Severity, Occurrence, and Detection rankings with ease.
  • Determine the unique qualities of the design and process.
  • Recognize and show the connections between Design FMEA and Process FMEA.

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SPC (Statistical Process Control)

What is SPC?

  • SPC is a method for analyzing, monitoring, and controlling processes using statistical methods and techniques. This helps to ensure that the process runs smoothly, resulting in more specification-conforming goods with less waste (rework or scrap).

 

Who should attend?

  •  Executives from businesses that want to use SPC to enhance and regulate their processes.
  •  Engineers, managers (middle and upper management), and supervisors who work on the shop floor to control processes.
  •  Individuals that actively participate in the creation, maintenance, and internal auditing of current or planned quality management systems.

 

  • Introduction, Process Control, Common & Special Causes
  • Process Control and Process Capability
  • Control Chart Basics, Elements of Control Chart
  • Exercise 1 X bar – R chart
  • Attribute Control Charts
  • Exercise 2 & 3 P Chart – U chart
  • Process Capability study
  • Analysis of control charts
  • Q&A

 

  • Understand the Purpose of SPC.
  • Understand Concept & Terminology used in SPC.
  • Learn to conduct & interpret results of SPC Studies for process controls or improvement.
  • Learn to apply control charts and the concept of Process Capability.

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5S

What is 5S?
  • 5S is a method of visual management that employs anything from floor tape to operations manuals. It’s not only about keeping things clean and organized; it’s also about increasing efficiency and profit. It is a framework that emphasizes the use of a specific mindset and set of tools in order to generate efficiency and value. It includes observing, evaluating, collaborating, and looking for waste, as well as the practice of waste removal.

Who should attend?

  • Any Company Employee
  • Factory Professionals
  • Students / Fresh Graduates
  • Trainers and Practitioners of Quality Management
  • Executives in Quality Management who want to brush up on their 5S knowledge.
  • Executives in Safety and Facility Management

  • Introduction to 5S
  • 5S philosophy
  • Implementation of 5S
  • PDCA cycle and 5S integration
  • How 5S is used in lean six sigma
  • Q&A
  • Complete methods for implementing 5S in any size company.
  • Practical Advice and Case Studies for Successful Concept Implementation.
  • The 5S Method for Adopting Lean Manufacturing
  • Techniques for Handling Resistance Change During Implementation

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