Trouble Shooting & Process Improvement

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Trouble Shooting & Process Improvement Quality Management


TROUBLE SHOOTING & PROCESS IMPROVEMENT

Duration: 2 Days
Time: 9.00am-5.00pm

Introduction

This training program provides participant with the concept of problem solving & trouble shooting. Implementing solutions without getting to the true root cause is a waste of money, time & resources. Traditional approach begin with limited info, many actions and lacking focus. Our approach focus on finding the true root cause before proceeding with actions.
 
With the increase in global competition, LEAN concept is introduced with the focus on reducing the Non Value Added (NVA) wastes for process improvement. Waste is anything that impedes the flow of the product as it is being transformed in the value chain. To maximize the efficiency of manufacturing/services, we will share the practices/tools from LEAN that can be used for continuous improvement towards operational efficiency/excellence.

Benefits

Upon completion of this program, participants will be able to:
  • Apply the 7 steps of Trouble Shooting
  • Understand basic concept of LEAN
  • Recognize the 7 wastes at the workplace for process improvement
  • Able to adopt relevant Lean practices/tools to identify opportunities for operational excellence at workplace

Key Content

MODULE 1-INTRODUCTION TO SIX SIGMA

  • DMAIC concept
  • Define, Measure, Analyze, Improve, Control
Objective: Understand the basic concept of 6 Sigma
Outcome: Determine the 5 elements of 6 Sigma
Hours: 1 hour

MODULE 2-WASTE IDENTIFICATION

  • 7 “deadly” wastes - TIMWOOD
  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Over-processing
  • Over-production
  • Defects
  • Value added/Non Value Added
 
Objective: Understand the benefits of 6 Sigma
Outcome: Determine the 7 benefits of 6 Sigma
Hours: 30 minutes

MODULE 3-TOOLS & TECHNIQUES

  • 7 QC Tools
  • Check Sheet, Pareto Chart, Fishbone Diagram, Scatter Diagram, Histogram, Control Chart, Graph
    • Brainstorming
    • 5-Why
    • 3MU elimination approach
    • 5W1H
 
Objective: Understand the basic tools of 6 Sigma
Outcome: Determine the 8 basic tools of 6 Sigma
Hours: 30 minutes

Module 4-7 Steps for Trouble Shooting

  • Problem Definition
    • Background
    • Specify Problem
    • Ideal State – Current State = Problem
  • Goal Setting
    • Quantify the problem - What, Where, When
    • Set goals (stretch)
  • Activity Plan
    • Timeline
    • Progress update
  • Root Cause Analysis
    • Identify Point(s) of Cause
    • Identify Root Cause
  • Generate & Implement Countermeasures & Corrective Actions
    • Identifies Solutions to Address Root Cause
    • Executes
  • Review Results (effectiveness)
    • Confirmed if goal(s) achieved
  • Standardized (Fan Out) & Share Learnings
 
Objective: Understand the essential steps of trouble shooting
Outcome: Apply the 7 steps towards effective trouble shooting
Hours: 5 hour

MODULE 5-WHAT IS LEAN?

  • What & Why?
  • Difference between Lean and Six Sigma
  • Lean concept in manufacturing/service and the benefits
 
Objective: Understand the basic concept of LEAN
Outcome: Differentiate the 3 key elements between LEAN and 6 Sigma
Hours: 30 minutes

MODULE 6-BUILDING LEAN CULTURE

  • Buy-in from management & staff
  • Link LEAN initiatives to departmental goals
  • Measure effectiveness of LEAN initiatives
 
Objective: Understand the basic concept of LEAN Culture
Outcome: Determine the 4 essentials to cultivate LEAN culture
Hours: 30 minutes

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