Day 1

• The quality challenge
  • Current expectations; industry differences
  • Nature of defects: random and rare
  • Proliferation of products/parts
  • High quality for least cost
  • Currently accepted principles
• Impact of lean manufacturing on quality
  • ZQC and Poka Yoke: quality system foundation
  • Pull/one-piece-flow: problems exposed
  • Cells and autonomation: defect reduction
  • Parts flow, Kanban, FIFO, WIP: defect control
  • Standardized work: abnormalities revealed
  • 5S and TPM: maintaining gains
  • Constantly attacking the 7 wastes
  • Visual management
• Technical tools of ZQC
  • Comparison to SPC/sampling/100% final inspection
  • Source and successive inspection
  • Quick feedback loop
  • Compared to the Deming circle
  • Poka-Yoke: mistake or error proofing
  • Errors: why they happen; errors and defects; human error
  • Using FMEA to determine error potential
  • Poka-Yoke: different levels; shop-floor implementation; using teams
  • Standardizing/auditing/maintaining Poka-Yoke systems
  • Creating a know-how book

 Day 2

• When defects occur: analysis methods
  • Quick feedback is critical
  • Isolate/control the problem
  • Set up recovery plan and repair team
  • Reaction speed
  • Use the 3 actuals and 10 whys
  • Analyze product first, process second:
  • Finding/verifying root cause
  • Communication throughout the process
  • Parallel analysis
  • Summary: the 6-step corrective action process
  • Manufacturing: influencing product design quality
  • Design for manufacturing and assembly
  • Product design: shop-floor input
  • Trial events: evaluating new designs
  • Benchmarking designs: Zenbara methods
  • Reducing product/part variety
• Management tools of quality
  • TQM: Why such a struggle?
  • Hoshin Kanri: from vision to results on the floor
  • PDCA: using it weekly
  • Using teams effectively
  • Quality problem ranking
  • Qualifying/auditing/ranking supplier performance
  • Qualifying new products/processes: detail inspection/function testing
  • Change control of product/process designs
  • Communication: building synergy
  • Role of the quality assurance department
    • Current role in a lean manufacturing plant
    • Routine activities
    • Exception handling
    • Engineering
    • Administration
    • Relation to other departments: authority issues
    • Workload analysis: right-sizing the quality department
    • Communication: building synergy