Details

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Trouble Shooting & Process Improvement

Duration: 2 Days

Introduction

This training program provides participant with the concept of problem solving and trouble shooting. Implementing solutions without getting to the true root cause is a waste of money, time and 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.

Course Objectives

• Apply 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

Module 2: Waste Identification

• 7 deadly waste - TIMWOOD
  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Over processing
  • Over production
  • Defects
• Value added/ non value added

Module 3: Tools & Techniques

• 7 QC tools
  • Check Sheet, Pareto Chart, Fisgbone Diagram, Scatter Diagram, Histogram, Control Chart, Graph
• Brainstorming
• 5 Whys
• 3MU elimination approach
• 5W1H

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 points of cause
  • Identify root cause
• Generate & Implement Countermeasures & Corrective Actions
  • Identifies Solutions to Adress Root Cause
  • Executes
• Review Results (effectiveness)
  • Confirmed if goals achieved
• Standardized (Fan Out) and Share Learnings

Module 5: What is Lean?

• What and why?
• Difference between lean and six sigma
• Lean concept in manufacturing/ service and the benefits

Module 6: Building Lean Culture

• Buy in from management and staff
• Link Lean initiatives to departmental goals
• Measure effectiveness of Lean initiatives

Target Audience

Technicians, Supervisors, Executives, Managers