TECHNICAL PROGRAMMES
1. TOTAL QUALITY MANAGEMENT (TQM)
COURSE CONTENTS:
- Introduction of TQM
- TQM frame work
- QC way of thinking
- Problem solving process
- Tools and Techniques
- Quality circles
- TQM system
- TQM process
- Essential pre-requisites
- 5S suggestion scheme, TPM & JIT
- Quality Assurance
- Kaizen
- QCD
- Achieving business purpose
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2. ISO 9001 – 2000 Q. M. S AWARENESS
COURSE CONTENTS:
- Effective application and use of the ISO 9001 QMS
- Understand the method of implementation
- Correlate the ISO 9001 – 2000 requirements with Total Quality Management concepts
- Method of conducting the internal audits
- Taking appropriate corrective actions for continual improvements
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3. ISO 9001 – 2000 Q M S INTERNAL AUDITORS TRAINING COURSE
COURSE CONTENTS:
- Understand the application of Q M S standards, method of planning and organizing for audits
- Understand the responsibilities of internal auditors
- Understand the method of implementation
- Correlate the ISO 9001 – 2000 requirements with Total Quality Management concepts
- Method of conducting the internal audits
- Taking appropriate corrective actions for continual improvements
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4. COST REDUCTION THROUGH ELIMINATION OF WASTE (MUDA)
COURSE CONTENTS:
- Canon –Toyota waste management system
- Fundamentals of Lean/Agile manufacturing
- Kaizen: Elimination of 3MU (MUDA/MURI/MURA)
- Cost of Poor Quality
- TPM- Six Major Losses
- 5S & Visual Management
- Productivity augmentation
- Setup Reduction
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5. 7 Q C TOOLS FOR PROBLEM SOLVING
COURSE CONTENTS:
- Importance of problem solving
- Methods of identifying problems
- Brain storming techniques
- Data collection and presentation
- Pareto analysis
- Cause and effect diagram
- Histogram
- Control chart
- Scatter diagram and Stratification.
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6. TRAINING ON TOTAL PRODUCTIVE MAINTENANCE
PRINCIPLES & PRACTICE
COURSE CONTENTS:
Outline of TPM
- What is TPM?
- Evolution
- Targets & Benefits of TPM
Understanding the Situation
- Analyzing the Losses
- Overall Equipment Effectiveness (OEE)
- Exercise
Autonomous Maintenance
- 8 Pillars of TPM
- Concepts of Autonomous Maintenance –Jishu Hozen
- How to Implement Autonomous Maintenance
- Seven Step Evolution
Implementing TPM
- How to Implement “Kobetsu Kaizen”
- Training & Tracking Methods
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7. 5 S HOUSE KEEPING
COURSE CONTENTS:
• What is 5S
• Basic principles 5S
• Why it is important
• Who should implement 5S
• Which is the right time to implement 5S
• How to implement 5S
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8. SINGLE MINUTE EXCHANGE OF DIE (SMED)
COURSE CONTENTS:
- Important Terms and Concepts
- Basic Steps in a Setup Operation
- The Three Stages of SMED
- Separating Internal and External Setup
- Converting Internal Setup to External Setup
- Streamlining All Aspects of the Setup Operation
- Techniques Viz.
- Use Functional Clamps
- Standardize Function, Not Shape
- 3. Eliminate Adjustments
- Action Plan
- Benefits
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9. FAILURE MODE EFFECT ANALYSIS (FMEA III EDITION - AIAG)
COURSE CONTENTS:
• Terms & Definitions
• Definition changes of Failure Modes
• Discussion on new inclusions: system, subsystem, and component
• Discussion on changes in severity ranking
• Occurrence table changes
• Changes in design controls
• Severity table changes
• Severity scale: internal and external customers.
• Example FMEA: Design & Process FMEA as per III Edition by hands-on exercises
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10. STATISTICAL PROCESS CONTROL TECHNIQUES
COURSE CONTENTS:
• What is SPC
• Need for change to SPC
• Variables and Attributes
• Common and special causes
• Distributions
• Measures of location (accuracy) and spread (precision)
• Central Limit Theorem (over view)
• Pre-control charts
• Rational Sub-grouping
• Process flow Chart
• X-bar and R chart exercise
• Control Vs specification limits
• Chart Interpretation
• Control Stability and Capability
• Process Capability Cp and Cpk
• Preliminary process capability Pp and Ppk
• Attribute charts c, u, p and np
• C chart exercise
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11. TRAINING PROGRAMME ON TOYOTA PRODUCTION SYSTEM
COURSE CONTENTS:
• High quality at low cost
• Manufacturing systems a review
• Frame work of TPS
• Pull manufacturing, JIT and Kanban
• Autonomation-Poke-yoke
• Jidhoka: People involvement and participation
Flexible Multi-skilled, cross functional workers
• Visible control system-5S and elimination of 3 MU
• Mixed model production – leveled and balanced production
• 7 types of waste – waste elimination
• Introduction to cellular manufacturing
• SOP – Takt time
• Reduced setup time
• Integrated quality control and preventive maintenance
• Vendor development/Integration
• Implementation Framework
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12. ENHANCE PRODUCT QUALITY AND PRODUCTIVITY AND THROUGH CONTROL CHARTS (IN TAMIL)
COURSE CONTENTS:
• Process Behaviour
• Normality and Normal Distribution
• X & R Chart
• Pre control charts
• Why the control chart works
• Control chart for fraction rejected.
• The control chart for non-conformities
• Statistical Analysis for process capability and for process improvements.
• Process capability studies.
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13. TRAINING PROGRAMME ON 8D PROBLEM SOLVING
COURSE CONTENTS:
• Establishing team membership, roles of the members, boundaries of freedom for the team, and getting the team started up.
• Developing the Problem Statement.
• Designing and putting temporary measures into place and verifying that they are working.
• Using a systematic approach to collect, display, and analyse data to identify the root cause(s). Verifying that the cause identified is truly the root cause.
• Finding a solution to attack the root cause and correct the problem. Using mistake-proofing techniques.
• Developing simple and complex action plans. Using Gantt and PERT Charts to plan the implementation and monitor progress. Finishing the job to ensure the problem does not come back.
• Ensuring training, audit practices, and knowledge transfer are completed. Providing recognition for the problem-solving team.
• Ensuring the problem-solving team recognizes those that have assisted them.
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14. TRAINING PROGRAMME ON IMPROVED PROFITABILITY
THROUGH COST REDUCTION IN MATERIALS MANAGEMENT
COURSE CONTENTS:
Session:1 Materials Management as a Profit Centre
Business Essentials in a competitive Environment - Key role of Materials Management in improving Company's Profits and Performance.
Session:2 Cost Reduction Through Strategic Sourcing
Strategic Sourcing as a business tool - Supplier Selection, Rating and Management of relationship – categorization of items.
Session:3 Cost Reduction Through Vendor Negotiations
Preparation, Data Collection, Analysing prices and costs - Setting targets and strategy - Stages of negotiations – Qualifications of a good Negotiator.
Session:4 Cost Reduction Through Vendor Quality
Analysing and improving incoming quality - Process study and quality improvement of vendors - Quality tools - Self Certification – Supplier relationship and continuous improvement.
Session:5 A Case study exercise
Opportunities & Challenges for Exports
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15. TRAINING PROGRAMME ON PRODUCTIVITY IMPROVEMENT TOOLS
COURSE CONTENTS:
• Necessity to improve productivity
• Method study and its constituent tools
• Measurement parameters
• Principles of motion economy
• Low cost automation
• The power of PDCA
• The Old and New QC tools
• CA / PA
• SPC
• Personnel productivity improvement
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16. POKA-YOKE- MISTAKE PROOFING
COURSE CONTENTS:
• ISO/TS 16949 requirements
• Need: Customer Delight
• Meaning and definition
• Evolution: Toyota Production System
• Introduction: Difference between SPC & ZQC- Low-cost !00% Automated inspection
• Human Error Syndrome
• Errors Galore: Errors Vs Omissions (Safety/Process/Assembly/ inspection /measurement & Packing)
• Basic Classifications of Poke-Yoke Systems
• Prevention Via Detection
• Alarm Vs. Shutdown Vs. Control
• Contact Vs. Fixed Value Vs. Motion Step methods
• Types of Sensors
• Examples of implementation in each case by reputed companies
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17. COMPETITIVE ADVANTAGE THROUGH LOGISTICS & SUPPLY CHAIN MANAGEMENT
COURSE CONTENTS:
Session 1: Overview of SCM – Current Business Scenario, Customer expectations, Challenges in Manufacturing, Definition of SCM, Key processes, Expectations of SCM
Session 2: Elements of SCM – Procurement, Manufacturing, Logistics, Warehousing & Distribution, Supply Chain Systems, Integration, Future trends, Benefits of SCM
Session 3: Logistics Management – Definition, Concepts, Elements, Integrated Logistics, Distribution, Logistics Costs, Third-party Logistics Provider (3PL), Benefits
Session 4: Information Technology – IT as an enabler, Components, Supply Chain Flows, IT integration, Technology and its impact, Processing tools and Benefits
Session 5: Case Study Exercise – Re-engineering the Supply Chain at ALPHA Ltd.,
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18. TRAINING PROGRAMME ON INDUSTRIAL HYDRAULICS – MAINTENANCE & TROUBLE SHOOTING
COURSE CONTENTS:
• Basic Hydraulic Symbols
• Types of Hydraulic Circuitry
• Maintenance Classifications
• Inspection of Hydraulic Installation
• Repair of Hydraulic Components
• Servicing of Hydraulic Components
• Hydraulic system erection & commissioning procedure
• Hydraulic System maintenance procedures
• Spare parts maintenance
• Logical Trouble shooting & Problem solving techniques
• Safety in Hydraulics maintenance
• Maintenance Documentations
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19. PREVENTIVE/PREDICTIVE MAINTENANCE PLANNING AND CONTROL
COURSE CONTENTS:
• Overview of maintenance
• Types of maintenance
• Maintenance policy
• ISO 9000/TS 16949 requirements
Preventive Maintenance (PM)
• Daily Maintenance
• Planned Maintenance
• Planning and Scheduling a PM
• Inspection Program
• Monitoring the PM Process
• Equipment for which preventive maintenance is best
Predictive Maintenance (PDM)
• On-line & off line
• Condition based maintenance
• Predictive Maintenance Techniques
• Equipment for which predictive maintenance is best
Maintenance Management
• Planning, scheduling & control
• Organization structure/skills
• Work order systems
• Logistics
• MIS
• Introduction to Computerized Maintenance Management System (CMMS)
• Spares control
• Maintenance control indices-performance measures
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20. EXPORT- IMPORT- (POLICY, PROCEDURE, BENEFITS) AND WTO
COURSE CONTENTS:
Forenoon Session:
• Salient features of Foreign Trade Policy 2005-2009.
• The role and importance of Directorate General of
Foreign Trade.
• Export-Import procedural framework.
• Overview of Duty Drawback scheme/Rebates and Refunds
Afternoon Session:
• Overview of WTO and obligations there under – Free Trade Agreements – Benefits of Industry.
• Overview of Advance Licensing Scheme,
DEPB/DEEC/DFRC/EPCE/EOU
• Self-Sealing facility for exporters
• Anti – dumping duty and safeguard duty.
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21. EXPLOITING PLANNING (PPC & MPC) PARAMETERS FOR
BETTER PERFORMANCE USING ERP
COURSE CONTENTS:
Understanding ERP
• Basics of Business Processes.
• Evolution of Systems and ERP
• Features of Enterprise Resource Planning
Master Planning
• Long Range Planning
• Forecasting
• Master Scheduling
Manufacturing Resources Planning
• Material Planning and Control
• Rough Cut Capacity Planning
• Capacity Resource Planning
• Distributed Resource Planning
• Production Planning and Control
Industry Specific Analysis
• Nature of Industry Vs Manufacturing Methodology
• Planning Exercises and Case studies
• Effect of Parameters on Performance – an analysis
• Overall Impact on productivity and customer satisfaction.
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22. (GD&T) GEOMETRIC DIMENSIONING & TOLERANCING
COURSE CONTENTS:
• Why Geometric dimensioning tolerancing?
• How the geometric system works
• Terms and definitions
• Common symbols & Terminology
• Fundamental Rules (Drawing)
• Feature definition - With Size and Without Size
• Material Condition (Maximum, Least, Regard of Material Condition)
• Limit Tolerancing
• Datum Reference Frame - Theory & Interpretation
• Datum Elements
• Form Tolerances
• Flatness, Surface Roughness
• Straightness
• Circularity, Average Diameter, Cylindricity, Orientation Tolerances
• Perpendicularly, Surface, One Datum Feature
• Profile Tolerances
• Position Tolerances
• Cylindrical Tolerance Zone
• Runout Tolerance
• Circular Runout
• Total Runout
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23. WORKSHOP ON COST REDUCTION THROUGH EFFECTIVE
VENDOR MANAGEMENT
COURSE CONTENTS:
Session I Vendor Selection & Approval
Preparation of a Questionnaire, process of visiting the prospective suppliers, assessing their capabilities, short-listing, placement of development order and approval of capable vendors
Session II Vendor Development on QCD
Extending technical and managerial assistance to upgrade the capability of the vendors in meeting the requirements of the company, relating to Quality, Cost and Delivery and enlisting them as Certified Vendors
Session III Vendor Rating, Vendor Meet & Improvement
Developing a Computerized Vendor Rating System, Organizing yearly Vendor Meeting to interact with Vendors for continuous improvement in performance
Session IV Long Term Vendor Relationship
A Case Study and Exercise on Vendor Relationship
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24. TWO DAYS TRAINING PROGRAMME ON INTERNAL ENVIRONMENTAL AUDITOR (ISO 14001:2004)
COURSE CONTENTS:
Day 1
• Understanding ISO 14001:2004 clauses from audit angle
• Understanding objective evidence required for each element
• Features of ISO 19011
• Internal Audits and Continual Improvement
• Audit Vocabulary
Day 2
• Principles of Internal Auditing
• Purpose and Scope of an Internal Quality Audit
• Design & Development of an Audit Plan and Schedule
• Developing Auditing Questionnaire/Check List
• Process approach to auditing
• Introduce attendees to the concept of audit trails
• Case Study & mock audit
• Non Conformity report writing
• Examination & Evaluation
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25. THREE DAY TRAINING PROGRAMME ON INTERNAL AUDIT-
ISO/TS 16949:2000
COURSE CONTENTS:
DAY 1
• ISO/TS 16949-2002 clause by clause requirements.
• Exercises on understanding of ISO/TS 16949-2002 requirements.
• Related core tools (APQP, SPC, FEMA, MSA)
DAY 2
• ISO 19011-2002 guidelines for Quality and /or Environmental system auditing
• Audit life cycle
• Internal Audit- planning and scheduling.
• Process Approach to Auditing.
• Practical exercises on turtle diagram, Audit planning and scheduling.
• Auditing skills.
• Audit check lists.
• Non-conformity report writing.
• Practical exercises on Non-conformity report writing.
DAY 3
• Automotive certification scheme for ISO/TS 16949-2002
• Third party audits.
• A guide to guide.
• Mock audits and audit reporting.
• Written test.
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26. INDUSTRIAL ENERGY COST REDUCTION TECHNIQUES
COURSE CONTENTS:
- Principles and fundamentals
- Energy Policy
- Energy costs
- Load Management
- Metering for energy management
- Lighting systems
- Utilities management like pumps, compressors- Efficiencies
- Combustion heat recovery and confinement
- Alternate Energy sources
- Energy information systems
- Energy conservation techniques
- Energy Auditing- Energy balance
- Introduction to Co-generation
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27. TWO DAYS PROGRAMME ON INTRODUCTION OF SGA ACTIVITIES
COURSE CONTENTS:
FIRST DAY
Session I
Japanese Workplace Management Vs. American Systems- Team Work Vs Individual Excellence –SGA, QC Circles, CFT, Task Forces
Session II
Evolution of Quality-PDCA Approach-7 Steps of Quality Improvement-Muda, Muri & Mura - Visual Management- Problem solving-Continuous Improvement
Session III
Overview of TPM-Autonomous Maintenance Groups
Session IV
Overview of 5S- Seri-Seiton-Seiso- Seikesu-Shitsuke
SECOND DAY
Whole day is devoted to understanding 7 QC Tools and using them in practical situations by individual, hands on graphical exercises. The intention here is to equip individual members of SGA with skill sets to enable them to apply these tools in problem solving situations of their companies.
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28. TRAINING PROGRAMME ON PNEUMATIC TECHNOLOGY
COURSE CONTENTS:
• Basic Pneumatic System
• Compressors Types
• Compressor Accessories
• Air Distribution
• Air Treatment
• Directional Control Valves
• Actuators
• Symbols & Basic Circuit
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29. TRAINING PROGRAMME ON INDUSTRIAL SAFETY
COURSE CONTENTS:
• Introduction
• Basic Principles of accident prevention
• Foundation of lost time injury
• Remedy
• Losses and responsibilities
• Hazards in material handling
• Hazards in handling electricity
• Hazards in various other work activities
• Protective clothing and equipments in reducing impact of injuries
• Case studies
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30. TRAINING PROGRAMME ON IMPROVING COST OF QUALITY THROUGH CONTINUAL IMPROVEMENT
COURSE CONTENTS:
• Quality and Conformance
• The Consequences of Non-Conformance-Loss of business, profits, productivity, liability & image.
Phase 1: Identifying the Cost of Quality
• The Cost of Poor Quality -Internal and External Failure
• The Cost of Achieving Good Quality -Prevention and Appraisal Costs
• The 7 Wastes
Phase 2: Collecting Cost of Quality Information
• COQ and Financial Analysis
• Matching of CONC Items
• Quality Costs and Quality Indices
• Quality Costing-methods
Phase 3: Analysing Cost of Quality Data
• Trend Analysis
• Pareto Analysis
• Setting Targets for Improvement
Phase 4: Reducing Cost of Quality and Improving Quality
• Reducing Cost of Quality and Improving Quality
• Continual improvement Tools and Techniques
• Quality Scorecard
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31. TRAINING PROGRAMME ON COST MANAGEMENT FOR COMPETITIVE ADVANTAGE
COURSE CONTENTS:
• Creation of database for Operational Control & Decision Making.
• Cost concepts in decision making
• Sell or Scrap,Retain or Replace and Repair or Renovate - Important decisions
• Marketing - Recent Trends in Cost Analysis
• Costing of Service Sector
• Why to relate Cost Management to Marketing, Management and Finance…?
• JIT,MRP,ERP,KAIZEN in Cost Management
• Activity Based Costing
• Value Chain Analysis
• Budgetary control and Performance Measurement
• Quality as a Competitive Weapon
• Balanced Scorecard - emerging concept
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32. TRAINING PROGRAMME ON EXPLOITING APQP AND PPAP FOR IMPROVING BUSINESS DEVELOPMENT
COURSE CONTENTS:
All five phases of product development. (APQP)
• Project definition and planning
• Product design
• Process design and development
• Product and Process validation
• Feed back assessment and corrective action
And Control Plan Methodology
Production Part Approval Process (PPAP)
• Part Approval process
• Requirements for Submission
• Customer Specific Requirement Deployment Matrix
• Part Submission Warrant
Analytical Techniques Used For Failure mode Identification and Prevention Brief Discussion
• Process Flow
• FMEA
• Cause and Effect analysis
• DOE
• Critical Path Method
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33. TRAINING PROGRAMME ON METAL FINISHING FOR ENGINEERING AND AUTOMOBILE INDUSTRIES (NICKEL, CHROME, ZINC & SILVER PLATING)
COURSE CONTENTS:
• Pretreatment for plating
• Zinc plating process – Cyanide free bath
Process – Trouble Shooting – Advantage & application
• Bright & dull Nickel plating
Process – Trouble Shooting – Application
• Bright & Hardchrome plating
• Silver plating
• For all the above plating topics discussed will be
Principle
• Process
• Electrolyte Composition
• Current density
• Maintenance of electrolyte
• Trouble Shooting
• Effluent Treatment
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