VE (Value Engineering)
Increasing competition for goods & services is not news anymore.
The problem that demands priority today is that of securing lower costs.
Value engineering is a combination of techniques, approaches & methods for achieving what the user or, customer wants at lower costs.
This course is aimed at sensitizing the present day professionals on to value aspects of business & to equip them with tools to enhance value creation.

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FMEA (Failure Mode & Effect Analysis)
Systematic analysis of potential failure modes is necessary to prevent failures.
It is better to initiate preventive actions before implementing new products, changes in products or processes.
Failure Mode and Effects Analysis (FMEA) is a tool to identify potential or actual points of failure and identify corrective action.

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SPC (Statistical Process Control)
Every data point possesses both a deterministic and a random component. If we only had perfect knowledge the random component would disappear.
SPC consists of statistical methods that use past experience to predict how the phenomenon may be expected to vary in the future.
SPC is more than the application of control charts and is used to tame manufacturing processes. It now extends to processes beyond those in manufacturing and is fundamental to maintaining a corporate competitive edge.

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SMED (Single minute exchange of dies)
Setup reduction is one aspect of Lean Manufacturing which is often ignored.
SMED focuses on reducing changeover & set-up times, thus enabling organizations to:

• Produce smaller lots of products & services more frequently
• Develop a broader scope of products & services
• Reduce quality defects towards zero
• Meet customers’ expectations

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PDCA (Plan, DO, Check, Act)
PDCA is unarguably the world’s most practiced problem solving methodology.
It is also one of the most effective. It is a unique combination of the left & right brain techniques that alternately diverge and converge the focus to facilitate “the right thing right the 1st time” approach.

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5S method of housekeeping
The discipline of 5S is a fundamental building block for Lean Manufacturing or the Lean Office.
Good 5S improves quality, cost, safety, the customer experience and enables World Class Performance.  It is easily applied to any business and any process, by anyone.
There are many reasons to begin Lean journey with 5S:

• It can be done today
• Everyone can participate
• Waste is made visible
• Has a wide area of impact

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Kaizen
Kaizen is one of the most powerful improvement methodologies and has been successfully used by the leading organisations as an improvement vehicle.
Kaizen is a means of continuing improvement in personal life, home life, social life, and working life.
The Kaizen business strategy involves everyone in an organization working together to make improvements without large capital investments.

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TPM (Total Productive Maintenance)
Reliability of processes and products is imperative to competitive advantage.
Equipment reliability is a precursor to product & process reliability.
TPM is not just a tool; it is a philosophy that has changed the fortunes of so many organisations across the world.
Effective utilisation of equipment brings in unimaginable benefits in terms of quality, cost and delivery.

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DPA (Departmental Purpose Analysis)
For an organisation to be customer driven, it needs to be process driven.
Process approach to work is a key differentiator and enables effective utilisation of resources and continuous process improvement.
Effective practice brings multifaceted improvements across organisational processes like shorter lead-time, waste reduction and improved efficiency.

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Lean Management
JIT is a philosophy of continuous improvement in which non-value-adding activities (or wastes) are identified and removed for the purposes of

• Reducing Cost,
• Improving Quality,
• Improving Performance,
• Improving Delivery,
• Adding Flexibility,
• Increasing innovativeness

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Kanban
Kanban scheduling systems are useful when lot sizes differ between process steps, processes are unbalanced or when distance introduces time lag or variability.

Kanban scheduling systems are often a transition between MRP (Material requirement planning) and ROP (Re-order Point) approaches and Physical Linkage.

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SGA (Small Group Activity)
Quality circles have been successful in empowering & creating ownership at workplace.
7-step Quality Improvement approach is based on PDCA, which is unarguably the world’s most practiced improvement methodology.
It is also one of the most effective. It is a unique combination of the left & right brain techniques that alternately diverge and converge the focus to facilitate “the right thing right the 1st time” approach.

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ISO 9001 (Quality Management Standards)
ISO 9001:2000 standard is one of the most popular quality system standards.
Its popularity overshadows its’ benefits. When implemented with heart & soul, it has the potential to bring unimaginable benefit to the organisation. It is the sure shot way to upgrade the organisation to next orbit of performance.

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DOE (Design of experiments)
DOE is a simple yet effective problem solving methodology.
It can be applied to problem resolution & also to problem prevention.
DOE supports quality improvement initiatives from primitive to world-class quality levels.

This training module explains Shainin techniques of DOE in a simple step-by-step approach.

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Six Sigma
Variation is the enemy.
The term Six Sigma is not only a statistical measure of variation; it is also a business strategy.
The Six Sigma philosophy has been adopted widely by all types and sizes of organisations throughout the world.

Six Sigma needs to be understood and integrated at every level of the organization if long-term companywide improvements are to be made.

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ISO 14001 (Environment Management Standards)
Ecological sense makes economic sense.
Long term sustainability requires environmental impact assessment & optimisation. This is best attained through understanding of environmental issues & organisation-wide participation.
Environment Management System (ISO 14001:2004) sets out to achieve continual improvement in environmental performance of the organisation through participation by all.

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Pokayoke (Mistake proofing)
The point of time, where mistakes & errors are corrected, decides the cost of the mistakes.
Based on the premise of 1-10-100 principle, Pokayoke has evolved as a leading methodology to prevent errors. Though simple in concept, it is the most effective method to prevent errors from becoming defects.

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OHSAS 18001 (Occupational Health & Safety)
Capacity to work at peak productivity is a key contributor to an organisation’s competitiveness.
Safety & health issues at workplace are tremendous opportunities to improve productivity. Identifying and improving these has positive bearing on workplace morale.
Occupational Health & Safety System (OHSAS 18001) provides a framework to organisations to address these issues and to continually improve.

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MSA (Measurement System Analysis)
Measurement is the first step to improvement.
Measuring right is even more important. Measurement System Analysis assesses the properties of a measurement system to ensure adequacy for a given application.

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7 QC Tools
7 QC tools are the most elementary SPC tools.
They are also very effective when utilised correctly.
The biggest advantage of these tools is the simplicity. Thus these could be used widely in any organisation by all levels.

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TQM (Total Quality Management)
TQM is an integrated organisational approach in delighting customers (both external and internal) by meeting their expectations on a continuous basis through everyone’s involvement.
It requires the organisation to work for continuous improvement in all products / processes along with proper problem solving methodology.

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COQ (Cost of quality)
COQ is a financial measure of the quality performance of an organisation.
It is essentially a measure of lack of quality & can also be termed as cost of bad quality.
An organization’s main goal is to grow & maintain high quality goods/ services.
With a comprehensive understanding of the costs related to quality this goal can be achieved.

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QFD (Quality Function Deployment)
QFD helps find the right things to execute.
While many TQM approaches focus on efficiency or experience in execution (doing things right the first time), this focus by itself will not achieve customer satisfaction. A company might simply end up doing a great job on something that its customers don’t care about.
The only way you can develop a sustainable competitive advantage over your competition is to pay attention to:

• what you do for the customer
• how you do it

 

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