• Advanced Product Quality Planning (APQP) is a methodology that encompasses all the activities and processes needed between customer concept and product launch. The business areas affected are technical sales, product engineering, reliability engineering, process engineering, and manufacturing operations. The purpose of APQP methods is to enable companies to reduce concept-to-customer time when creating new products and maintaining a high-quality level with minimal launch difficulties.

• Measurement System AnalysisThis workshop presents the basic concepts related to reducing measurement variability. During the workshop participants will perform analytical work to evaluate the effectiveness of gages brought to the workshop. Forms for performing gage R&R studies and sample parts will be supplied as part of the course.

• Process Auditing for Process ImprovementThis is an interactive course that involves hands-on:

-Key process selection

-Metrics identification

-Process auditing

This program includes process auditing classroom training and insights, wrap up and reporting. The training portion of this program is outlined as noted in the “Training Course Content.”

This program is customized to meet your needs and can accommodate groups of 15 internal auditors.

• Process Failure Mode & Effects Analysis (PFMEA)This is an interactive course that addresses how failures occur; the effect, causes, and severity of the failure; the likelihood that the cause will result in the failure; mechanisms to detect failure; reliability of the detection mechanisms and the risk associated with the failure. Some classroom activities include process mapping, process analysis and creating a PFMEA.

• Process Mapping for Continuous ImprovementProcess mapping is an easily understood visual representation of a process. The process map is used to analyze the flow of events through the process and to identify where improvements can be made. Frequently, a process map is used in a Team Problem Solving setting to assist in analyzing a process and determining where error or defects may occur. Process map symbols also identify the types of activities and events that are a part of the process. This course includes a section on how to use a process map to analyze and improve processes.

• Production Part Approval Process (PPAP)The purpose of the Production Part Approval Process is to determine if all customer specification requirements are properly understood and that processes have the potential to produce products meeting these requirements. The workshop covers the PPAP requirements as established by DaimlerChrysler, Ford and General Motors.

Statistical Process ControlStatistical Process Control (SPC) is widely used in manufacturing to control and ensure quality products. Statistical methods are reviewed and concepts of probability and variation are introduced. Attribute and variables control charts are constructed and then interpreted for in-control and out-of-control conditions. A heavy emphasis is placed on interpreting control charts.

• Overview of ISO/TS 16949This course provides participants with a high level of understanding and appreciation of the ISO/TS 16949 standard. The intent of the course is to provide participants with enough background and understanding of their role in supporting the company’s certification to the standard.

• Team Problem Solving In today’s complex business environment, finding the root cause of a problem is often a very difficult task. While a single individual might sometimes be able to solve certain problems, the more complex problems in business are better addressed by a multi-disciplinary team. In Team Problem Solving, each member of a group brings their collective experience to solve the task of getting to the root of a problem. This workshop focuses on a structured eight-step methodology used to find the root cause, determine how to permanently solve a problem and prevent its recurrence.

• Advanced Geometric Dimensioning & Tolerancing Geometric Dimensioning & Tolerancing is an engineering tool used to accurately describe parts and manufacturing tolerances. Basic GD&T is reviewed and advanced concepts are discussed and applied in a workshop format. Attention is given to applying GD&T in the “real world.”

• Business Operating System (BOS)This workshop will introduce the concepts of the Business Operating System (BOS) by outlining the major steps required to implement an efficient system of measuring performance. The workshop also includes the review process that ensures performance goals are being met.

• Design Failure Mode & Effects Analysis (DFMEA)Reducing product development time and providing the defect-free products is a vital competitive strategy. Failure Mode and Effects Analysis (FMEA) is a planning tool that is applied to the design of a product or process. FMEA enables a cross-functional team to identify and prevent problems from occurring. During this interactive seminar, participants will have an opportunity to apply the concepts of DFMEA to a company project.

• Design of ExperimentsExperiments is used in manufacturing to design robust products and processes. Designed experiments rely heavily on statistical methods to determine a variation within trials and between trials. Variation is the key to determining if two or more trials show significantly different results. This course includes a basic review of statistics and then covers the more common experiment designs. In the manufacturing environment, proficiency at the Design of Experiments allows optimal settings of process parameters.

• Lean Manufacturing OverviewCompanies responding to cost pressures understand how lean principles and techniques can improve operations, reduce costs and increase profit margins.

• Poka-Yoke/Mistake Proofing is a fundamental part of Continuous Improvement when the process “meets” product. Defects, errors and accidents are all results of either a “poor” process or product design. Mistake proofing techniques provide the strategy to improve both project and process performance while taking into account all the traits of human interaction.

• SMED Quick ChangeoverFrequent setups are necessary to produce a variety of products in small lots. In order to become more flexible, there is a need to focus on reducing setup time and using the techniques of the Single Minute Exchange of Dies (SMED) to meet challenging customer requirements. SMED refers to a theory and the techniques for performing setup operations in fewer than ten minutes – the number of minutes can be expressed in a single digit. This course is an introduction to inexpensive techniques that can be used to achieve quick changeovers.

• Total Productive Maintenance (TPM)TPM is a company-wide, team-based effort to improve output quality while decreasing input, accomplished through equipment care that improves overall equipment effectiveness. Participants learn that TPM combines the practice of preventive/predictive maintenance with Total Quality Control and Total Employee Involvement, to create a culture where operators develop ownership of their equipment and become full partners with Maintenance, Engineering and Management to assure equipment always operates properly.

• Value Stream Mapping (VSM)Value stream mapping is a valuable tool used to create value and eliminate MUDA (waste). The value stream map is the most important tool used to make sustainable progress in reducing MUDA. Create a value stream map and learn to use it to differentiate between value and waste and to get rid of the waste. The value stream map lets you identify every process in the flow. It should be used every time a change is made to any process or flow.

• 5S5S uses simple highly effective techniques to remove waste from your work environment through better workplace organization, visual communication, and general cleanliness.

• Visual WorkplaceBuild upon the 5S approach to housekeeping through the visual location of items and equipment, Kanban control, inventory, safety, performance reporting, job instructions, and more.

• Leadership and communication in any workplace, problems can arise that are often attributed to attitude, motivation, morale, or communication problems. Often, the root cause of these problems can be directly linked to poor listening skills. This interactive workshop will explore barriers to effective listening and tips for improving the quality of communications in any setting. Students will also learn about their personal listening profile and the steps that they should consider to make themselves better listeners.

• Holding Effective Meetings Improve the efficiency of your workforce by making every minute count. This seminar will investigate methods to make your meetings more effective and value-added.

• Leading the Change Process Change is a constant in the modern organization. Leaders of the change process need management skills in order to reduce or eliminate frustration, “culture” shock and defensiveness. Participants in this workshop learn how to properly implement change while minimizing resistance.

• Managing Conflict Conflict must be managed positively for the organization to operate effectively. Learn how to recognize the difference between healthy and harmful conflict, and how to develop a strategy for controlling and possibly resolving destructive conflict. Students will also use the Dealing with Conflict Instrument to better understand their conflict behavior.

• Performance ManagementThe high-performance organization requires dynamic leaders who can fully develop the potential of the firm’s most valuable assets — employees. This seminar examines the specific skills needed to manage and motivate professional and salaried employees. Managers, Directors, and staff will explore their roles and how they relate to the skills needed to carry out these roles. These concepts will be explained and reinforced through multiple small group activities. Workshops will focus on the proper use of existing systems and procedures.

• Team Building and Group DynamicsTeams are the way we do things. Building effective teams is essential to our success. Through the use of workshops and small group activities, supervisors will understand their role in the modern organization and will learn to apply the basic skills needed to help the organization and their team to succeed. The full two-day seminar is appropriate for new teams. Existing teams will find value in Part II, Team Dynamics. Part I is presented on the first day of the seminar, and Part II is presented on the second day.

• Essential Skills for Professional ManagersThe high-performance organization requires dynamic leaders who can fully develop the potential of the firm’s most valuable assets – its employees. This seminar looks at the specific skills needed to manage and motivate professional and salaried employees. Managers, Directors, and staff will explore their roles and how they relate to your company’s mission. Specific skills needed to carry out these roles will be explained and reinforced through multiple small group activities. Workshops are focused on the proper use of existing systems and procedures.